fasterz
03-01-2012, 02:23 PM
Finally with some time and money I am doing a complete overhaul on my ’04 450r. I am doing nearly all of the work with a few exceptions, by myself so I figured I would start a build thread for others follow and see just how easy a lot of the work can be done right at home. This over haul will include the following work:
- Abrasive Blast Parts
- Soda Blast Engine Parts
- Powder Coat Nearly Everything on the chassis
- GT Thunder Rear Linkage w/ Revalving
- Rebuild Elka Fronts and have them set up better by GT Thunder
- New Crank and Bearings from Honda
- All New Valve components from Honda
- JE 11.5:1 Piston for Pump Fuel
- Rage ATV 5 Angle Valve Job and MX Porting
- New Full Exhaust System
- And More!
Here are some pics after the Wildwood Beach Race Last October, hence the large tires...
http://img.photobucket.com/albums/v242/fasterz/IMAG0478.jpg
http://img.photobucket.com/albums/v242/fasterz/IMAG0479.jpg
http://img.photobucket.com/albums/v242/fasterz/IMAG0480.jpg
After Pulling the Entire thing apart, here is what I was left with...
http://img.photobucket.com/albums/v242/fasterz/100_1309.jpg
There were a few small cracks from all the abuse I give it so I added some more reinforcement to the top frame rails by cutting tubing in half and welding it over the factory tubing...
http://img.photobucket.com/albums/v242/fasterz/100_1310.jpg
I also re welded the steering upright since it has some small cracks on both sides. I used my Eastwood MIG175 to do all the welding which is a 220v 175 amp MIG welder...
http://img.photobucket.com/albums/v242/fasterz/100_1313.jpg
I blasted the larger chassis parts with an Eastwood abrasive blaster using ground glass for media...
http://img.photobucket.com/albums/v242/fasterz/100_1314.jpg
Here is the frame all blasted and ready for powder...
http://img.photobucket.com/albums/v242/fasterz/100_1315.jpg
After a pre bake I put the powder on hot and laid it down thick for the best protection and durability, if your wondering it took about a half pound to do the entire frame...
http://img.photobucket.com/albums/v242/fasterz/100_1326.jpg
Here it is after baking it...
http://img.photobucket.com/albums/v242/fasterz/100_1327.jpg
I also did a number of other parts this day, the colors I used were Metallic Blue, Black Star Dust, and Reflective Chrome which require a clear coat on top...
http://img.photobucket.com/albums/v242/fasterz/DSC_0483-e1329230276554.jpg
http://img.photobucket.com/albums/v242/fasterz/grabbar.jpg
http://img.photobucket.com/albums/v242/fasterz/metallicbluehub.jpg
http://img.photobucket.com/albums/v242/fasterz/100_1329.jpg
I then started pulling the motor apart for the complete rebuild and as I pulled it apart I soda blasted a lot of the parts using Eastwoods small soda blast kit which made these pieces look like new, wait till you see the final motor assembled it will look like it came off the factory line...
BEFORE:
http://img.photobucket.com/albums/v242/fasterz/100_1335-1.jpg
AFTER:
http://img.photobucket.com/albums/v242/fasterz/100_1336-1.jpg
I have a long way to go on this project and will update once I get a day to make some more progress! Let me know if you have any questions on doing any of this stuff!
- Abrasive Blast Parts
- Soda Blast Engine Parts
- Powder Coat Nearly Everything on the chassis
- GT Thunder Rear Linkage w/ Revalving
- Rebuild Elka Fronts and have them set up better by GT Thunder
- New Crank and Bearings from Honda
- All New Valve components from Honda
- JE 11.5:1 Piston for Pump Fuel
- Rage ATV 5 Angle Valve Job and MX Porting
- New Full Exhaust System
- And More!
Here are some pics after the Wildwood Beach Race Last October, hence the large tires...
http://img.photobucket.com/albums/v242/fasterz/IMAG0478.jpg
http://img.photobucket.com/albums/v242/fasterz/IMAG0479.jpg
http://img.photobucket.com/albums/v242/fasterz/IMAG0480.jpg
After Pulling the Entire thing apart, here is what I was left with...
http://img.photobucket.com/albums/v242/fasterz/100_1309.jpg
There were a few small cracks from all the abuse I give it so I added some more reinforcement to the top frame rails by cutting tubing in half and welding it over the factory tubing...
http://img.photobucket.com/albums/v242/fasterz/100_1310.jpg
I also re welded the steering upright since it has some small cracks on both sides. I used my Eastwood MIG175 to do all the welding which is a 220v 175 amp MIG welder...
http://img.photobucket.com/albums/v242/fasterz/100_1313.jpg
I blasted the larger chassis parts with an Eastwood abrasive blaster using ground glass for media...
http://img.photobucket.com/albums/v242/fasterz/100_1314.jpg
Here is the frame all blasted and ready for powder...
http://img.photobucket.com/albums/v242/fasterz/100_1315.jpg
After a pre bake I put the powder on hot and laid it down thick for the best protection and durability, if your wondering it took about a half pound to do the entire frame...
http://img.photobucket.com/albums/v242/fasterz/100_1326.jpg
Here it is after baking it...
http://img.photobucket.com/albums/v242/fasterz/100_1327.jpg
I also did a number of other parts this day, the colors I used were Metallic Blue, Black Star Dust, and Reflective Chrome which require a clear coat on top...
http://img.photobucket.com/albums/v242/fasterz/DSC_0483-e1329230276554.jpg
http://img.photobucket.com/albums/v242/fasterz/grabbar.jpg
http://img.photobucket.com/albums/v242/fasterz/metallicbluehub.jpg
http://img.photobucket.com/albums/v242/fasterz/100_1329.jpg
I then started pulling the motor apart for the complete rebuild and as I pulled it apart I soda blasted a lot of the parts using Eastwoods small soda blast kit which made these pieces look like new, wait till you see the final motor assembled it will look like it came off the factory line...
BEFORE:
http://img.photobucket.com/albums/v242/fasterz/100_1335-1.jpg
AFTER:
http://img.photobucket.com/albums/v242/fasterz/100_1336-1.jpg
I have a long way to go on this project and will update once I get a day to make some more progress! Let me know if you have any questions on doing any of this stuff!