2001 YZ250 makeover

[ThumperTDC]

So I am helping a buddy redo his 01 YZ250 for his High school senior project. He is installing a hurricane kit, but is doing his project on powder coating so we are tearing it all down to get it coated. Here is the kicker, we are installing 02 to current plastic all the way around. Got an 02 tank and made the new brackets to mount it up. Got an 02 sub frame to mount the 02 airbox, seat, and number plates to. Obviously there was some work needed to be dont to make the sub frame fit, but it was nothing at all to make it fit. Cut, grind and reweld and it was on there. We are also doing something trick which you will see in the pictures.

Before pics:



Here are some pictures of the progress:

Cutting about 1/8 inch off the upper sub frame mount on the right side so the new subframe will bolt up.


With the sub frame bolted to the upper mount, shows how far off the lower mounts are:

Right side:


Left side:


Mock up pic before cuttin/welding:


Grinding after cutting off lower sub frame mounts:


Sub frame on the bike after lower mounts were cut off:


Right lower subframe mount tack welded in place:


Left lower subframe mount tack welded:


The trickness, boxing in the frame:




Going black on the frame and wheels, the hubs will be yellow as well as the motor mounts, the plan is also to polish the sub frame and swing arm. We are also going to be adding an 18inch rear wheel as well as a coolant overflow bottle.

New pics 3/12/09:

Finished boxing in the frame and threw some pain on it so it would show up better for the camera.

Right side:


Left Side:


3/22/09
Got the stuff powder coated last sunday and today we started putting the bike back together.



The work I did on the frame




3/24/2009
So here are some more pics from this morning. Some more parts should arrive today so if I can get the wheels laced up for him today, the bike should be together tomorrow other than finishing up the wheels.





As I get new pictures, I will simply add the pics to the original post, for ease of viewing.

I'm also getting my XR400 podercoated and am doing some mods to the frame so I will start another thread with those pics as I get them in. This sunday is when everything is getting powder coated so we have to have everything ready by then.

[Y2K YZ250]

Looking good!! talk about a complete face lift...

[A-310]

Originally Posted by ThumperTDC

So I am helping a buddy redo his 01 YZ250 for his High school senior project. He is installing a hurricane kit, but is doing his project on powder coating so we are tearing it all down to get it coated. Here is the kicker, we are installing 02 to current plastic all the way around. Got an 02 tank and made the new brackets to mount it up. Got an 02 sub frame to mount the 02 airbox, seat, and number plates to. Obviously there was some work needed to be dont to make the sub frame fit, but it was nothing at all to make it fit. Cut, grind and reweld and it was on there. We are also doing something trick which you will see in the pictures.

Before pics:



Here are some pictures of the progress:

Cutting about 1/8 inch off the upper sub frame mount on the right side so the new subframe will bolt up.


With the sub frame bolted to the upper mount, shows how far off the lower mounts are:

Right side:


Left side:


Mock up pic before cuttin/welding:


Grinding after cutting off lower sub frame mounts:


Sub frame on the bike after lower mounts were cut off:


Right lower subframe mount tack welded in place:


Left lower subframe mount tack welded:


The trickness, boxing in the frame:




Going black on the frame and wheels, the hubs will be yellow as well as the motor mounts, the plan is also to polish the sub frame and swing arm. We are also going to be adding an 18inch rear wheel as well as a coolant overflow bottle.

As I get new pictures, I will simply add the pics to the original post, for ease of viewing.

I'm also getting my XR400 podercoated and am doing some mods to the frame so I will start another thread with those pics as I get them in. This sunday is when everything is getting powder coated so we have to have everything ready by then.

Nice work and keep us posted. One question though, why did you box the frame? Cheers

[ThumperTDC]

Originally Posted by A-310

One question though, why did you box the frame?

Well it was an idea I had, and mentioned it to my buddy. He kinda liked the idea so we ran with it. Something different, kinda like the newer aluminum frames. Thought it would look pretty sweet when it is done. I finished the other side last night and think it looks better than the first one, but I still have some finish work on them before I would say they are finished to my likings. Sure it will add some weight to the bike, but it should be down low and not that noticable. We are making a woods bike out of it so it shouldn't matter to much.

[Y2K YZ250]

I thought about making some plates like that for my bike out of stainless so my boots wouldn't rape it, maybe this summer.....

[ThumperTDC]

Stainless would look sweet.

[cowboyona426]

It was so purdy in blue, now you're gonna ruin it?
Nice work man, and nice to see you hanging around here. Looking forward to the "after" pics!

[ThumperTDC]

Finished the frame and posted new pics. The powder if flyin Sunday, so I will try to get some pictures up then of everything coated.

[ThumperTDC]

New pictures added 3/22/09

[ThumperTDC]

New pics added 3/24

[Ford]

Nice work, it looks sharp!!!!

[ThumperTDC]

Pretty much got it finished up yesterday other than the tank/shroud graphics and finishing up truing up the wheels and installing them.

Have to have it all complete by Friday since that is when my buddy has to display the bike at school, so hopefully it should b e done Thursday night.

[Ford]

Fantastic job!....damn you can eat off that engine head it so clean. Sweet looking ride Thumper. So good yours makes mine look bad, lol!


Cheers!

[ThumperTDC]

Well it'snot my bike, it is a buddies bike that I was helping him out with his high school senior project..........which was on powder coating. I just did all the fab work for him.

It is amazing what some aluminum wheel cleaning acid and a hot water from a pressure washer can do, it was really dirty before.

[Ford]

LOL, nice job though i like the yellow plastics, looks sharp!

[A-310]

wow, very sick. Nice job, nice to see the older YZ's looking awsome.

[ThumperTDC]

Finished the bike this morning. I talked my buddy into removing the front and side number plate background since they looked kinda cheesey. I think it turned out looking pretty sweet.

The camera died after taking just the one picture and here she is all finished.



and yes after the picture was taken I realized the chain was not in the chain guide and has been since fixed.

[AJ_YFZ]

Really nice looking bike....that frame turned out nice...the fabricating and the powder...
Now the real question.... Is he gonna ride it?

[ThumperTDC]

It's together so he can have it for display at school tomorrow since that was the due date for this project. We still have a couple of minor things to do and then he is going to be able to go ride it.

[Ford]

again thats an excellent job!.......enjoy when you get the chance to take it for a boot!


waaaahooo!

Ford