F'dup DR650 Supermoto- Project: Heavy weight hooligan <BUILD THREAD> - Custom Fighters - Custom Streetfighter Motorcycle Forum

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Old Streetfighter Motorcycle Forum Post 11-01-2014, 12:58 PM   #1
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Default F'dup DR650 Supermoto- Project: Heavy weight hooligan <BUILD THREAD>

It's time y'all...

So here is a up to today wrap up from the thread in the "dirty tard" sub-forum I started.

Started off with two Dr650's and stripped them both down to bare frame and assembled one out of the good parts from both.



Got the two bikes built into one stock example of a Dr650.





Started chopping up a 2013-2014 CRF450 dual exhaust and combining them with a 06-09 CRF250 mid pipe.





Welded the 450 mufflers to the 250 mid pipe. I did this because I didn't want to use the round mufflers off the 250, I wanted to keep the squareish 450 mufflers. The 250 mid pipe is nice because the inlet diameter matched the dr650 pipe unlike the 450 inlet and would be easier to work with. Also gave me more room by the airbox and shock.





Cut some off of the uglier Dr650 head pipe to give me room to run the exhaust.



Zip tied on mock up pic.





Then I got super lucky and scored a warp-9 supermoto wheel set on ebay at a reasonable price. Came with 17" wheels, pilot tires with ~1000 miles on them, corrected speedo drive, warp 9 320 floating rotor and caliper bracket and a shorty side stand. Which as turns out stand is WAY too short, don't know what they were thinking there lol I'll redo that one.







After I put the wheels on and grabbed those pics I went back at the exhaust. It was still incomplete and zip tied on in those pics.

First de-tab the subframe. Things like old exhaust mounts, and grab handle mounts got cut off.





Removed this mount.



Burned in a new one.



So, that leads us up to where I am at today as far as work on the bike.

Here are the proof of date pics to make it all legal.








2017 build off sv650 build thread <---Click here

SV650 b.s.'n and post build off progress on the bike thread thread <---Click here


DR650 supermoto build <--click

2000 R6 build <--click

Quote:
Originally Posted by RS_Raz View Post
A bit of vaseline should lube your bush up real nice though. Just make sure that your shaft is a good fit.
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Old Streetfighter Motorcycle Forum Post 11-02-2014, 06:50 PM   #2
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Default Re: F'dup DR650 Supermoto- Project: Heavy weight hooligan <BUILD THREAD>

Spoiler alert: Video at the end of the post. Probably have to click the photo bucket link as I can't ever get embedding right on here lol...

Right so the exhaust situation. Need to bridge this gap.



I cut the inlet end off the muffler and that piece is the perfect diameter to slip into the new inlet end on the CRF250 mid pipe.





With that part cut short I was left with that above gap to bridge between the head pipe and the mid. So I started cutting out the new piece to weld in.



Eventually got the piece down to a good weldable size and had at it burning it in. Not easy on the eyes, but I never claimed to be a good welder lol. Although I have come a LONG ways ...



Once the mid and the head pipe were joined I went about the muffler brackets. I cut the rubber mounts off the old muffler to help dampen the vibes at the mounts.



Out of pure luck they ended up being the perfect fit for the muffler mounts!





Then I went about goobering those in place.





With both sides goobered on both edges this is how they are looking all mounted up!







If you were wondering, here is pics of clearance between airbox, frame, and shock with the new exhaust.









Only less than ideal part is the clamp on the mid, I got it at the only spot that is accessible with any tool and I can just get a ratchet wrench on there to tighten it up. Should've thought that one out a little better, but I can get it tight so oh well.



So enough pics and talking lets hear how it sounds! Personally I love it, not stupid loud not lame quiet...

http://vid301.photobucket.com/albums...psqrg5c23t.mp4

Thanks for looking y'all, I'll be back later to get the price list posted up....

2017 build off sv650 build thread <---Click here

SV650 b.s.'n and post build off progress on the bike thread thread <---Click here


DR650 supermoto build <--click

2000 R6 build <--click

Quote:
Originally Posted by RS_Raz View Post
A bit of vaseline should lube your bush up real nice though. Just make sure that your shaft is a good fit.
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Old Streetfighter Motorcycle Forum Post 11-02-2014, 08:38 PM   #3
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Default Re: F'dup DR650 Supermoto- Project: Heavy weight hooligan <BUILD THREAD>

This will be for everything up to today. The rest will be posted as I put it on and totaled at the end.

Price list:
(2) 2001 DR650's $1550
Supermoto wheel setup $750
Crf450 mufflers $275
Crf250 mid pipe $30

2017 build off sv650 build thread <---Click here

SV650 b.s.'n and post build off progress on the bike thread thread <---Click here


DR650 supermoto build <--click

2000 R6 build <--click

Quote:
Originally Posted by RS_Raz View Post
A bit of vaseline should lube your bush up real nice though. Just make sure that your shaft is a good fit.
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Old Streetfighter Motorcycle Forum Post 11-09-2014, 04:19 PM   #4
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Default Re: F'dup DR650 Supermoto- Project: Heavy weight hooligan <BUILD THREAD>

Pic dump time

What happend this weekend.

Trimmed the inner fender to get that back in and past the new exhaust.





And she is in.



With that sorted I threw it loosely back together to get some pics. Loosing those grab handles and back blinkers cleaned up the ass end pretty good.





Biggest issue (stupid large tail light and plate holder aside) is the number plates. Left is flat up against the exhaust and right is out way too much for the size of the new muffler. That will be addressed further down the road.



Picked up a black UFO supermoto fender, cause the stocker is a bit huge. I'm sure y'all know how to mark and drill four holes in plastic so lets just stick to the "after" pics.









Picked up a KTM 625smc headlight. I like these because you still get an H4 bulb, so it puts out good light, but it's a smaller package than the stocker.



Stoopid easy to mount. Take off the rubber fork straps and then use those holes to bolt it onto the stock DR650 headlight mount Got real luck here.





All I needed to do was add a couple of spacers behind to two bolts.





Pics with it on.









That's about it. Need to move speedo and dash around to clean things up a little more upfront but I'll tackle that later.

Thanks for looking and sorry about all the pics

Parts:
S/m fender $26.95
KTM light $30.00
Spacers and hardware "Free from the parts horde."

2017 build off sv650 build thread <---Click here

SV650 b.s.'n and post build off progress on the bike thread thread <---Click here


DR650 supermoto build <--click

2000 R6 build <--click

Quote:
Originally Posted by RS_Raz View Post
A bit of vaseline should lube your bush up real nice though. Just make sure that your shaft is a good fit.
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Old Streetfighter Motorcycle Forum Post 11-16-2014, 03:33 PM   #5
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Default Re: F'dup DR650 Supermoto- Project: Heavy weight hooligan <BUILD THREAD>

Stuff that needs to go.



Some of what needs to go on. RM250 rear fender, unsure of year I've had it in the horde since the days of my 400.



Chop chop.





Add a little RM to the mix.



Roll her outside for some mock up shots since it's not a snow covered ice berg in CT....Yet...

A before shot for comparison.









Thanks for looking guys. And thanks for the high fives too! Got to get back out and try and figure out just how I'm going to make that new fender happen...

2017 build off sv650 build thread <---Click here

SV650 b.s.'n and post build off progress on the bike thread thread <---Click here


DR650 supermoto build <--click

2000 R6 build <--click

Quote:
Originally Posted by RS_Raz View Post
A bit of vaseline should lube your bush up real nice though. Just make sure that your shaft is a good fit.
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Old Streetfighter Motorcycle Forum Post 11-23-2014, 06:44 PM   #6
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Default Re: F'dup DR650 Supermoto- Project: Heavy weight hooligan <BUILD THREAD>

Had to move this stuff around.





Dash apart with a ruff plan on aluminum... You know, cause ever ounce counts...



Holyos... And more filing than I would like to discuss...





It fits!



It fits... Again..



Out the way. Speedo next.



Just whipping up a drop bracket, and if you don't have a drill press I would %100 recommend the harbor freight one that I got. So much better than a hand drill.



Bolted up to original mount on triple and some new hardware and spacers on the bottom holes.



That's better.






2017 build off sv650 build thread <---Click here

SV650 b.s.'n and post build off progress on the bike thread thread <---Click here


DR650 supermoto build <--click

2000 R6 build <--click

Quote:
Originally Posted by RS_Raz View Post
A bit of vaseline should lube your bush up real nice though. Just make sure that your shaft is a good fit.
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Old Streetfighter Motorcycle Forum Post 11-30-2014, 03:44 PM   #7
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Default Re: F'dup DR650 Supermoto- Project: Heavy weight hooligan <BUILD THREAD>

Some people build with a plan, some people like me, don't...I tend to just mess around with stuff and when something seems to click I move forward. So today I started messing with the rear fender.

Got some supplies, 2 packs of modeling clay (the stuff that doesn't harden), a clay shaping tool set, aluminum tape, packing tape, great stuff and some glue.



Cut off this cross bar. That was behind the remaining stock fender.



Slid the piece of the new RM fender underneath and glued them at the top where they made contact. Sliding underneath allowed me to shorten the length about 1" from the mock up pics.





Packing taped off the area underneath going from frame rail to frame rail then sprayed the great stuff in. This was done to give the fender some support.



So the "plan" I got is to trim away the foam and then I'll use the clay to reshape the RM fender to tie it all into the stocker. I may have to wait a day or two for the spray foam to harden.

So next post the clay work will begin. Thanks for looking y'all

Arts and crafts store and Home depot supplies: ~$50

2017 build off sv650 build thread <---Click here

SV650 b.s.'n and post build off progress on the bike thread thread <---Click here


DR650 supermoto build <--click

2000 R6 build <--click

Quote:
Originally Posted by RS_Raz View Post
A bit of vaseline should lube your bush up real nice though. Just make sure that your shaft is a good fit.
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Old Streetfighter Motorcycle Forum Post 12-07-2014, 04:38 PM   #8
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Default Re: F'dup DR650 Supermoto- Project: Heavy weight hooligan <BUILD THREAD>

Cut foam.



Get in touch with my inner 6 year old.





Start working the rainbow technicolor dream fender.











Tools I've been using.



So far I am surprised at how easy this is going. I actually said to myself, "Holy shit, this may just work." It's really slow going, but do-able. As you can see I have a lot of shaping left to do but I will chip away at it. Could only get a little time in today as I had to work yesterday, and I'm fighting mono symptoms... Fucking skanks....

Best part of the clay is the material you scrape off just gets balled up and you can reuse it to fill in low spots and rework.



Thanks for looking and for the high fives and comments! Still don't have a "plan" for the fender but I'm happy with how the clay is working so I feel good moving forward!

2017 build off sv650 build thread <---Click here

SV650 b.s.'n and post build off progress on the bike thread thread <---Click here


DR650 supermoto build <--click

2000 R6 build <--click

Quote:
Originally Posted by RS_Raz View Post
A bit of vaseline should lube your bush up real nice though. Just make sure that your shaft is a good fit.
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Old Streetfighter Motorcycle Forum Post 12-14-2014, 08:08 PM   #9
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Default Re: F'dup DR650 Supermoto- Project: Heavy weight hooligan <BUILD THREAD>

Fender progress. It's slow going, but working with clay is proving to be surprisingly easy!

Had to cut the last bit of down slope out of the remaining stock fender to give me a straight line.







Started removing clay. Used that line as my bottom reference.



Started shaping the fender out.







Got the left side to a good point then started messing with the right side. Still work to be done on both sides, but I'm happy with the progress at this point.







And possible the best part of the weekend. Hooked up a florescent light above the bike, and I picked up a sweet ass table lift for $300 off a buddy of mine! No more working in the dark and no more sore back for me!



Thanks for looking y'all!

2017 build off sv650 build thread <---Click here

SV650 b.s.'n and post build off progress on the bike thread thread <---Click here


DR650 supermoto build <--click

2000 R6 build <--click

Quote:
Originally Posted by RS_Raz View Post
A bit of vaseline should lube your bush up real nice though. Just make sure that your shaft is a good fit.
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Old Streetfighter Motorcycle Forum Post 12-21-2014, 05:10 PM   #10
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Default Re: F'dup DR650 Supermoto- Project: Heavy weight hooligan <BUILD THREAD>

So remember when I said I didn't have a plan? Well that was really dumb....
I was trying to get things symmetrical on both sides of the fender and trying to work out the bottom edge and it wasn't going good...

Then this happens.





I flipped the fuck out and tore off the clay and ripped that hateful bull shit off the bike.

I reached a low point and considered just buying the $165 dollar pre-made straight fender.

Then after I cooled down I said, "This is customfighters for fuck sake that's not how we do it here!"

So a plan was hatched. Yes now I have a plan...

Center line and outside edges of fender mark out on a Ikea furniture laminated board type of thing and fender piece aluminum taped down.





Marked my fender tip spot using the rest of the stock fender tip.



Use a square and mark reference lines across the board.



Trim the tip piece down a little and slide it under the back half piece. Then aluminum tape it down.



Shit ton of card board and aluminum tape to cover the hole and build the fender tip piece up some.



Start throwing on the clay.



So good news now I have reference lines to see where to stop the different areas of clay work. And I also have a good flange around the edge for my mold, which is a huge improvement over doing it on the bike.

I'll be back at shaping the clay soon and obviously post pics as I progress.

Thanks for looking guys!

2017 build off sv650 build thread <---Click here

SV650 b.s.'n and post build off progress on the bike thread thread <---Click here


DR650 supermoto build <--click

2000 R6 build <--click

Quote:
Originally Posted by RS_Raz View Post
A bit of vaseline should lube your bush up real nice though. Just make sure that your shaft is a good fit.
F'dup is offline   Reply With Quote on our streetfighter motorcycle forum
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