Fasterz's '04 450r Build Thread

[fasterz]

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!

[Foxhound013]

Looks good man! I wish we still had the our powder oven, I would've already had mine apart and powdered if we did lol. What color plastics you gonna go with?

[chronicsmoke]

Looks really good! Subscribed for updates :cool:

[trx400Rider]

lookin good so far. you gunna change the tires? the rears atleast, there huge mud tires!

[fasterz]

Well after a long wait I finally have some updating to do as I have made a huge amount of progress.

I got back to doing some more soda blasting with Eastwood's small soda blast kit which works so great its addicting and making me want to soda blast every aluminum piece. I soda blasted the cases, check out the difference:

Before:
http://img.photobucket.com/albums/v242/fasterz/100_1349.jpg

After:
http://img.photobucket.com/albums/v242/fasterz/100_1350.jpg

After Cleaning everything up and installing all new bearings it was time for the crank install. I had a heck of a time trying to find out how to assemble the 'updated' crank so here is a pic for those who don't know which direction the new collar goes:
http://img.photobucket.com/albums/v242/fasterz/100_1357.jpg

Then finally everything started going together. I got most of the motor built without the head and got it in the chassis since I was waiting on the head from Rage Atv. Check out how nice and new all the cases look after being soda blasted. Its awesome because it doesn't take away any metal like abrasive blasting does its just a super cleaner. For the piston I ended up going with a 12:1 JE so that I can run pump gas. Id like to thank East Coast Cycle Center for hooking up great deals and customer service on all of the OEM parts as well as some of the aftermarket stuff. Mike S is one helpful guy who will compete with online pricing and get things to you ASAP.

http://img.photobucket.com/albums/v242/fasterz/100_1444.jpg

http://img.photobucket.com/albums/v242/fasterz/100_1445.jpg

I had quad rate dual adjust Elkas and wasn't the happiest person with them and they were also due for a rebuild so I sent them to GT Thunder and they did their conversion as well as an overhaul on the shocks. Well see if they perform better than Elkas set up which I thought was terribly harsh compared to the axis I had on my old Suzuki.
http://img.photobucket.com/albums/v242/fasterz/100_1446.jpg

Sorry for the bad lighting here there was too much sun to take pictures. Here is some more of the chassis being assembled. Note the GT Thunder rear conversion with their linkage.

http://img.photobucket.com/albums/v242/fasterz/100_1443.jpg

Then... Finally... after nearly 6 weeks of waiting, my head showed up from Rage! I originally sent him all new oem parts to replace everything but he talked me into some stainless ferrea intake valves since I am running a stage 2 hot cam. I went with their MX / recreation porting, which looks great but well see how it runs as I have never had them do a motor for me but I have heard nothing but great things!

http://img.photobucket.com/albums/v242/fasterz/100_1458.jpg

http://img.photobucket.com/albums/v242/fasterz/100_1456.jpg

I am hoping to finish the build this weekend and will get some quality pictures before heading to Budds Creek next weekend if all goes well!

[fasterz]

Heres two shots before it all goes together. Unfortunately I needed to order a dowel pin for the head and over nighted it so it'll be able to go together tomorrow!
http://img.photobucket.com/albums/v242/fasterz/100_1460.jpg

http://img.photobucket.com/albums/v242/fasterz/100_1459.jpg

[twink07]

Hey man I got a stage 4 elka shock u might want looking for 500 shipped

[fasterz]

Here are some finished pics! Now off to Budds Creek for the National this weekend.
http://img.photobucket.com/albums/v242/fasterz/finished1.jpg

http://img.photobucket.com/albums/v242/fasterz/finished2.jpg

http://img.photobucket.com/albums/v242/fasterz/finished3.jpg

http://img.photobucket.com/albums/v242/fasterz/finished4.jpg

http://img.photobucket.com/albums/v242/fasterz/finished6.jpg

http://img.photobucket.com/albums/v242/fasterz/finished7.jpg

[Balaz_73*00]

Looks good man! Red rears would look good imo. That pipe is sick

[Balaz_73*00]

How'd the bike perform?!

[400eXz]

Darn nice looking bike, im looking to do the same to my bike this winter, but purple frame and white sub frame. and white plastics with spastic graphics! get some new rear plastics and it would look super nice!