Pbr

[Jake250ex]

and no, I aint talkin about pabst blue ribbon. Its time for a poor boy rebuild

[Jake250ex]

here my bike before. I didnt get any good before pics but its nothing fancy at all. your basic, used, dirty 05 450r

http://s14.postimage.org/we4wpgv4h/302051_275407185833364_100000922540798_851890_20.j pg (http://postimage.org/)

[Jake250ex]

the above picture was the night before Ironman which was my 2nd costly DNF in a row so I decided it was time to tear this thing apart. I has gone thru 2 top ends in 2 races.

and I apologize in advance for the low quality pics their all taken from my blackberry

[Jake250ex]

I am doing this to show you dont need to dump thousands into your bike to make it look nice. So this thread is gonna be about putting alot of time and effort into my bike and doing what I can on a tigh budget.

My first order of business was the motor. The crank seized up before I even got into the woods at Ironman as well as blowing another new top end.

I pulled the motor and it had baked on oil from where it spewed it all out and it looked terrible. I got a wire wheel out and buffed the cases then hand polished it with some mothers. Heres a picture of the before and after

http://s18.postimage.org/6va801mex/378408_314915551882527_100000922540798_968818_19.j pg (http://postimage.org/)

[Jake250ex]

I searched the net everywhere looking for the best deal on motor parts... I found a guy on ebay selling a new hotrods crank for 200 shipped then in his description he said he as all the other parts to rebuild the bottom end and would make a deal so I sent him a message.

He sent me new OEM crank bearings and seals, the hot rods crank, an oem oil pump, oem engine gasket set and a new oil strainer for $300 shipped. The motor already has a new sleeve in it (that needed re bored), new timing chain, new kibblewhite valves, hrc cam and new timing chain guides.

Had a local guy Dan Watson do the motor, a hill climb guy. He decked the head for me where the last guy that did my 2 top ends pressed the sleeve in and left it uneven with the top of the cylinder and also took a dial bore down the sleeve and found that the last guy also had the bore very badly tapered, causing it to seize up when it got to temp...

http://s14.postimage.org/8m9u2je6p/image.jpg (http://postimage.org/)

[Jake250ex]

Then I found a 96mm wiseco piston brand new on ebay for 80 bucks shipped. 10.5:1 compression, pretty mild but should last a while. the added cc's should make up some power

http://s15.postimage.org/hjrr440ij/image.jpg (http://postimage.org/)

[Jake250ex]

so at this point I have 380 in parts for a full motor rebuild and 200 in labor.

so $580 for a full motor rebuild, not bad. Wish I would have just done this in the first place.



assembling it on the kitchen table :devil:

http://s15.postimage.org/dmdo66sgr/vdfv.jpg (http://postimage.org/)

[Jake250ex]

Still havent put the cam on and adjusted the valves I'll probably get that dont today and get the motor in.

but now onto the frame. When the motor popped it blew hot oil all over the frame which got dirt in it, aside from all the rub marks from me legs where it was rusting... It looked like crap.

I stripped it all down and sanded all the spots with chipped paint with 220 to even and smooth it out then scotch brighted the rest. I read on here that dupli color t229 rattle can was close to the stock color so I got a couple cans and went at it. I think its pretty close...

http://s15.postimage.org/xdjoha6cb/vsdv.jpg (http://postimage.org/)


rattle canning anything gets a bad rep... but if you take your time and prep it properly and actually get decent paint it can come out pretty good. Of course its not going to be as durable as powder coat but Ive put 3 cans of paint on my frame, a arms and motor mounts so Ive got about $22 dollars in it so compare that to PC.

[Jake250ex]

the only thing that might not be accessable to everyone I did on this project is take advantage of my dad working at a body shop...

I had him clear coat everything I painted at his paint booth to make it shine a little and make it more durable

http://s14.postimage.org/j3m3t2avl/fgbf.jpg (http://postimage.org/)

[Jake250ex]

One big thing I want to stress with my rebuild is details. Im taking basically every nut and bolt to the wire wheel and cleaning it up. Putting a greasy dirty bolt thru freshly painted a arms and frame def knocks off a few points...

http://s16.postimage.org/iyo9vpvad/bfg.jpg (http://postimage.org/)

[Jake250ex]

got the a arms and front shocks on

http://s18.postimage.org/j3ocueb3t/dfv.jpg (http://postimage.org/)


http://s13.postimage.org/6s9e3wghz/yujn.jpg (http://postimage.org/)

[Jake250ex]

got the motor, swingarm, subframe steering stem on today

http://s12.postimage.org/axg0x3za5/dfb.jpg (http://postimage.org/)

[Jake250ex]

http://s18.postimage.org/xehkzwiix/bgb.jpg (http://postimage.org/)

[Scro]

Looks nice. I like the fact you are using stock colors, you don't see it very much with rebuilds.

[mx Eli]

need more of these top to bottom in and out full rebuilds! I love em

[chronicsmoke]

Looks clean man! you need some PBR to help you finish your PBR though ;)

[Jake250ex]

Originally posted by Scro
Looks nice. I like the fact you are using stock colors, you don't see it very much with rebuilds.

I just wanted it to look like a new stock bike when it was done. I dont have any really flashy parts so I thought it would look kinda silly with a different colored frame and most of the stock parts

[Jake250ex]

The only thing at the point I wish I would have done is paint the sib frame. The color doesnt match up, which isnt a huge deal because it doesnt match a new stock frame either but it just looks a little odd with a shiny clean frame and the old subframe.

One thing that I was worried about would kill the look of it is the old grimy chain. Im doing this project and only putting the bare necessities into it so a new one wasnt in the budget, and you guys all know what an old rusty chain looks like. I wish I would have got a before pic but I buffed it, top, bottom and both of the sides and it looks like new. Ill get a pic.

I wish I had a better camera it looks alot better in person these pics are hazy

[Jake250ex]

got some random pics with a REAL camera.

got the oil cooler, radiator, spindles/hubs, and started on the wiring harness today

http://s18.postimage.org/gql10ap5l/100_0249.jpg (http://postimage.org/)

[Jake250ex]

http://s12.postimage.org/l4l8no60d/100_0250.jpg (http://postimage.org/)

[Jake250ex]

http://s13.postimage.org/3yt2okb6v/100_0252.jpg (http://postimage.org/)

[Jake250ex]

http://s16.postimage.org/xpl97g2it/100_0253.jpg (http://postimage.org/)

[Jake250ex]

http://s18.postimage.org/sm2prcp95/100_0255.jpg (http://postimage.org/)

[Jake250ex]

http://s14.postimage.org/rlg97gcdt/100_0257.jpg (http://postimage.org/)

[Jake250ex]

http://s18.postimage.org/drnb4nuft/100_0256.jpg (http://postimage.org/)

[Jake250ex]

wish I had a rear shock or even a spring to match the fronts. The only things bothering me about it now is the case saver mounts are broke and radiator is tweaked a bit... I think I might make a case saver that mounts to the stator cover. Should have it almost finished tomorrow

Also wanna add that in the spindle pics all I did was spray meguiars chrome wheel cleaner on them and scrub them with a scotch bright real quick... The stuff is awesome but its super strong you gotta rinse it off pretty quick or it'll leave your aluminum looking white and chalky

[Jake250ex]

Read in the 400ex forum that you can wetsand and buff your plastics... Gave it a shot today and ruined my plastics. Its super cloudy and theres a ton of compound burnt into the plastic. Wish I woulda know I was gonna waste a day and ruin my plastics before I tried it.

My dad can paint, im thinking about to just re sand them and paint it. At this point, Im not sure what else to do. they look like crap and I dont want to buy a new set. Paint looks awesome... for a while. Until it flips and the fenders flex. I dont mean spray painting it, it would be done right in a booth and cleared and all that good stuff.

If I woulda known I was gonna do this I woulda gone with the color scheme I wanted with an orange frame and yellow plastics

[JGilkerson]

Lookin good man. Dan Watson is good guy!