Project DR is underway

[kro]

After the DR recently suffered a top end failure, while I am waiting to find suitably priced 2nd hand bits, I am going to strip the old girl to bits, and start with a bare frame rebuild. I am going to take photos on the days I work on it, and itemise all expenditure, so that all you lads and lasses can see that you can rebuild an old clunker to look like a tidy little beastie on a tight budget. We are a one income family, and subsequently, I will be doing everything as cheaply as I can. I have got the pre-strip down photos done, just ignore the dates on the photos, my stupid camera won't hold the date for some reason.
I am waiting to find a top end, head/valves/cam etc in workable condition, so I'm on the hunt for DR/GN top ends at the moment, most of which are beyond my budget, so If you hear of any going cheap, maybe even a wrecked GN, please let me know.

I will update this original post here with everything I spend.

SPENT SO FAR
$4.00 on two cans of Supercheap Degreaser - Supercheap.
$13.00 - Heat proof 1350* ceramic paint - Repco (used on exhaust)
$15.00 - Anodising effect paint - Duplicolor - Repco (used on alloys)
$20.00 - 2 cans of VHT grey primer - Repco (used on frame)
$12.00 - 2 paint/stripping wheels - Warehouse
$24.00 - 2 cans dark grey paint - Duplicolor - Repco (used on frame)
$23.80 - 3 new rear wheel bearings - Engineering and Bearing Nelson.
$10.00 - 1 can black gloss - Duplicolor - Repco. (will be used on rear wheel)
$10.90 - Paint Stripper - Septone - Supercheap.
$6.80 - Assorted wet and dry sheets (4x) - Repco
$10.50 - Autosol - Repco. I finally used my old tube up, it was 2 years old, already halfway thru this new tube.
$4.50 - Norton sanding block - Supercheap (awesome idea, foam block, covered in wet and dry grit)
$4.00 - Norton Wet and dry paper, x 4 sheets - Supercheap.
$7.90 - Nuts/bolts/washers (hi tens and SS) Blacks fasteners Nelson (awesome service btw)
$42.00 - SGP Front brake cable - Nelson motorcycle Centre
$25.00 - Front brake lever assembly (complete) - Nelson Motorcycle Centre.
$30.00 - Brand new YZ250 rear guard, and 2 sidecovers - TardMe (silly person didn't know what they were worth)
$50.00 - Seat Recovering, and foam padding repair - Fenemors Upholstery Nelson. (Great job done too)

First installment of photos taken 10 mins ago................

[Boosted]

Good stuff :) hope it comes out a minta :D

[GR81]

SPENT SO FAR
$4.00 on two cans of Supercheap Degreaser
$13.00 on heat proof Black enamel paint.
i hope you havent hit budget already :blah:

[barty5]

some cheap stuff pops up on ebay just check theyll send down here 1st

[kro]

Ok, spent an hour on it last night, pulling allsorts of things off it, and storing them safely, or labelling them, seeing as I am a complete novice backyard mechanic.

I should have some more pics up the next couple of days too.

[paturoa]

you haven't mentioned the running cost of beer

[kro]

Beer is more a way of life, and is categorised under "overheads", therefore it does not appear on the list. Besides, if i did list it, you'd all say to me, "why not just buy another bike with all the money you wasted on piss?". That's hardly sporting is it?.

[cheese]

Far out you ever clean that bike?

Give it a massive wash down before you pull more out.

I use

one scoops of washing powder adn hot as you can stand water.

scrub the shit out of it and hose it down.

[cheese]

Far out you ever clean that bike?

Give it a massive wash down before you pull more out.

I use

one scoops of washing powder adn hot as you can stand water.

scrub the shit out of it and hose it down.

[kro]

The one time I had not cleaned my bike is the time you see photos of it. The bike is/was religiously maintained and cleaned. I was saving up dough for a piston and rebore when the top end went screwy louie on me.

I use truck wash on it, spray on, hose off, minty fresh clean. She's gonna look like a beast when I have finished.

[cheese]

I was just winding you up mate.

Are you going to paint up your frame as well?

[kro]

I am indeed Mr Cheese. I was wondering whether to make the frame dark blue, or leave it black, I haven't quite decided yet. I think because it's not a full cradle frame, I may not get a good effect by painting it blue, like a later model DR, what do you think?.

[cheese]

Personally I think that anything other than black or silver looks old..... Dark blue however could look quite nice. Depends how dark........ Might be a bugger to clean.......

Had a gander on ebay for bits?

[cheese]

Looky looky

http://search.ebay.com/search/search.dll?sofocus=unknown&sbrftog=1&from=R10&satitle=DR250+%2B+suzuki&sacat=-1%26catref%3DC6&sargn=-1%26saslc%3D2&sadis=200&fpos=ZIP%2FPostal&ftrt=1&ftrv=1&saprclo=&saprchi=&fsop=1%26fsoo%3D1&coaction=compare&copagenum=1&coentrypage=search&fgtp=

http://cgi.ebay.com/ebaymotors/93-Suzuki-DR250-Cylinder-and-head-top-end_W0QQcmdZViewItemQQcategoryZ35595QQihZ005QQitem Z150020516870QQrdZ1

Classy

http://cgi.ebay.com/ebaymotors/red-white-SKULL-gripper-seat-cover-Suzuki-DR250-90-99_W0QQcmdZViewItemQQcategoryZ34284QQihZ017QQitemZ 270016799071QQrdZ1

[kro]

Thanks cheese, but all that stuff is for 90's upwards DR's, mine is a lowly little 1982, so my parts are harder to find. I basically need a GN top end to get going. Ideally, a wrecked GN, or just the head, and I can ride again.

[cheese]

try Baileys in Hawera (I think) or atomic in auckland. If you find something at Atomic, I could ptrobabyl pick it up for you adn ship it on our work rates ($9.95 to nelson for 15kg)

[kro]

I tried Baileys, they sent me a dud, it had allsorts of bits missing. A head fromAtomic was gonna be half of what I paid for the whole bike 6 months ago, and I could not really afford it.
I'm not trashing Baileys by the way, very helpful, and good communication.

[oldguy]

Good luck with your project mate, I,m pissed with mine at the moment, for the life of me I can't get it going. so it been sitting in the shed where I dont have to look at it. Hope you find your bits you need, will keep an eye out for bits for yeah.

[kro]

Sorry to hear bout the DR oldguy, I want to eventually own a mid to late 90's DR350, I have ridden a couple, and they just feel good, and are a good old low maintenance air/oil cooled thing.
Gonna do an update tomorrow, I stripped a few bits off the bike, and got em painted today, so I'll do a couple of before and after photos.

[far queue]

I was wondering whether to make the frame dark blue, or leave it black, I haven't quite decided yet. I think because it's not a full cradle frame, I may not get a good effect by painting it blue, like a later model DR, what do you think?.How about Metalic Dark Grey, like the current DR's?

[kro]

Not a bad idea. I am concentrating on getting the frame prepped for repainting tomorrow, and weather depending, getting a coat or two of primer on it, so I'll have to decide very soon I guess.

How hard is it to take the forks off a bike. I just want to remove them to make it easier to get the frame painted. The last set of head bearings I touched was on a pushbike, and were a bugger of a thing to reset, to get the tension just right, without crushing the bearings, or leaving it too loose, and getting play.

Help a rookie out yall !!!

[Ghost Lemur]

Don't know about putting back together. But pulling the forks off is easy. :D

[Danger]

Kro, you could remove the front wheel and the forks but leave the tripple clamps on the bike if you wanted to and just mask them up and paint around them. Or its probably a good idea to service the headset bearings anyway and remove them. One step at a time, remove the wheel, then the forks, then the tripple clamps.

[kro]

Thanks heaps Danger, I followed your instructions, and all is going according to plan, although, I am getting very carried away with painting, and the likes, I think this is going to turn into a very thorough rebuild, the bike is going to look MAGIC when it's finished.
More pics later this afternoon.

[kro]

I got a fair bit done today, but forgot to photograph some of it, here is a before shot of the middle section of the exhaust, and the after shot is both the header (duh), and the middle pipe.

The third shot is an experiment, it's the alloy lever from the front brake, which I cut back to a high shine, and covered with a paint which gives a very cool anodised effect. I will probaly regret it, but I cut back my entire top clamp, and painted it with this stuff, and man oh man does it look awesome. I will post a pic of it tomorrow.

[Ghost Lemur]

That blue looks mint. The frame would look very cool in a metallic blue, particularly if the plastics are going to be a more neutual(sp?) colour. Remember the guy floating around a while back with the custom kwaka, silver (with some sort of sparkles) plastics with a metallic blue frame. That looked mint.

[kro]

I looked at the idea of making the frame that same blue colour, but the paint requires an absolutely perfect clean, oil free, and dry surface, which looked like it was going to be a mission on a huge surface area like a frame, so I am going to strip the frame back today, and see what I decide at the end of it.
I think for practicality's sake, I should really use a good hard enamel, and for that reason, I think I'll just primer it, and stay with the original black frame.

More photos later today.

[kro]

Ok, first picture is the frame, nearly all taken back to metal, took about another half hour to take it all back. I wasn't going to take it all back, but after discovering a few bad rust spots, I decided to go the whole hog on it, then I know she's all good.

2nd pic is the grand unveiling of the KTM-esque black hub, with black spokes. I am going to autosol the rims to death, but after I get the wheel back in the front assembly, as its way easier to just spin the wheel, with ya polishing rag pressed against the rim. I was forced to paint the spokes, as they were all rusty, it took ages to get the worst of the rust off, geez was I cursing by the end of that job.

3rd pic is the original top clamp, sprayed in Duplicolor brand Metal-Cast paint, which gives a very nice anodised effect. I found out though, that this chips easily, so I will have to clear coat it too. Hopefully it can be clear coated, otherwise it will look pretty beat up before too long.

Pics of a fully primered frame tomorrow, courtesy of VHT primer, and a few minutes of breathing paint fumes, which is always fun on an empty stomach.

Dinner time for me.

[kro]

Here is the primered frame, looking very nice indeed. It spent hours last night perched on top of a gas heater to dry properly. Swingarm is being polished, and having the nicks and bumps smoothed out. I was hoping to jam the front end back together today.

[cheese]

Shit hot mate! you're going to make that old bike look like new!! That blue stuff looks awesome!!! I'm getting tempted to do my bike now. I'll wait till I send my cyclinder off to get re-nikasiled.

[kro]

More pictures due tomorrow, I didn't work on it last night, instead had a night off, seeing as I had been working on it for 6 days straight. I may have found the parts I need, I'll will know this afternoon.
Hopefully the painting I have done so far will be dry enough to clear coat, and then I can polish the forks up, and get the front end back together tonight.

[kro]

Bah, silly visitors meant I got sod all work done on the bike. I did sneak away for half an hour, and made a buffing wheel, and autosol'd the death out of one of the forks very quickly, and hells bells did it come up good, and that was just a quick buff, I can't wait to see how good they look with a proper polish up.

[cheese]

Everytime I read this I get inspired to do some work on my bike, but then I think.... yeah I'll do it later.......

[kro]

I'm fully addicted to the project, it's all I want to do. I had school variety concert last night for my son in the juniors, that went till 8.30, and tonight my daughter in the middle syndicate has hers, and Friday, I have to go represent my company at the bloody Contractors Federation dinner, so I have 3 damn nights this week that I can't do anything on the bike, and I'm suffering !!!.

Looks like the weekened is going to be when I get everything done now. I finished polishing up one fork last night,, had to get all the oxide off with some wet and dry, then got the buffing wheel, and Autosol onto it, and now it looks damn near new. That was a massive 15 minite job :P .

I have had to do some serious alterations to the airbox. The damn thing had 3 extra intakes added to it, and they were all really badly done, and all caused water to leak past the hoses they has used, and pool water in the bottom of the airbox, which explains a bit of misbehaving in the engine dept when going thru lots of water, or deep water.
I have plugged and welded all extra inlets bar one, which I used a highly flexible polymer sealant to seal up, and I will paint the whole airbox, hopefully tonight, if I can sneak 15 mins of time before the concert.

[kro]

Just to break the monotony of my boring resto', here is what bikes are to me these days. Not far over the Maungatapu track , you hit a wee valley, off which is this little river, that runs crystal clear all the way down to Pelorus.

[Ivan]

Hey Kro I admire your dedication,
Keep the hard work up

[kro]

Thanks Ivan.

Due to my sister in law turning into a raving psychopath, I have not done very much work on the bike this weekend, and in the interests of family safety, I have shipped my wife and children off to blenheim, and they have the digital camera with them. DOH. I reassembled the forks, and they look fantastic after a buff up, and paint. I have the rear suspension side of things looking pretty damn sweet too. I will try get another camera to use.

[kro]

Just a couple of quick photos showing the near finished front end, and a couple of the rear suspension components, like the pivot, and A-arm.
Note the lovely shiny forks, I love Autosol, I wonder if it would make good toothpaste?. Sorry bout the crappy quality pics, I am using a 70 dollar dicksmith special at the moment.

I am undecided about the blue anodising effect paint. I have baked it on, and clear coated it, but time will tell I guess. Basically, every nut, bolt, washer, bracket etc is all being polished painted, or clear coated, so it will look a million bucks when it's finished, then I'll go get it dirty.

Bought all new rear wheel bearings today, the fronts had been done recently, but the backs were worse than i thought. I have updated my costs so far list in my original post.

[aff-man]

what did you use to strip back the frame. Got me a couple of ag100's that i'm rebuilding and would be keen to know how you did it / how long it took?

[kro]

Quickest way is to get one of those flexible paint stripper wheels, the spend 10 mins going over most of the major surfaces, but only to scuff them up, then spray the whole thing with paint stripper, leave for half an hour, hose of very quickly, then use the stripping wheel to get rid of the stuff that the paint stripper aerosol didn't move. I was surprised how easy it was.

[cheese]

Man that is incredible how well that all came up! I can;t wait to do project RM!!!!

[Ghost Lemur]

Great work kro.

She's looking mint. I'm definitely taking note. Love my bike. HATE the painted white frame. Might be my winter project next year.

Looking forward to the next update.

*damn between this thread and sprokets' carbon thread I'm learning shitloads*

EDIT: Oh, and I think the blue looks Hawt.

[kro]

Thanks troops, there should be another few pics today, I'm getting my better camera back, and will take photos of the frame this afternoon, and the front wheel/hub assembly all back togther, and looking sparkly.

[PZR]

Well I must say I am impressed what you can do with care and love and a side order of fanatical devotion. It should look amazing when finished. I particurlarly like that blue paint. Where did you say you got it from?

I have been doing up an old KDX myself which I just got started on the weekend so know how much work can go into tidying up an old beast and I sure did not bother with making mine look pretty. Be careful of the restorers trap many fall into. You do it up so well its near perfect them become scared to use it in case you break/scratch it. Its an easy trap to fall into. Been there done that.
But hey, enjoy yourself, I am looking forward to seeing more pictures
Well done

[kro]

PZR, the blue anodising effect paint is sold at both Supercheap, and Repco, it's called Duplicolor Metalcast. You can get alloy color, purple, green and blue (I think)

Thanks for the comments troops, but to the horror of some of you, this bike will get ridden, and will get hell filthy again, but at least I know she's fully rebuilt, and everything on it works as it should, and has been replaced/revamped. I will be taking approx a hundred photo's during the whole project, and plenty more after the last item is bolted back on, and she's fired up for the first time.

[kro]

Sorry, I am still using that shit-box cheapo camera, so most of these photo's look poos. Pretty self explanatory, the frame has had its second coat, and it's gonna get a couple of clears, more as a sacrificial coating thatn anything to do with looking fancy-schmancy. Frame is a dark grey colour, it looks quite lioght in the photo, but it's not.

Front wheel looks better in the flesh than in the photo, bear in mind, I ma yet to autosol the rims, then the whole rig will cease looking good, and start looking fantastique.

Foot note, if you look hard at the frame as a whole in the 2nd frame pic, it looks like a metal sculpture, of a guy doing a girl doggy style, I just noticed it, how trippy is that shit?.

[kro]

Quick question to you bike experts, the little studs that hold the sprocket to the rear hub assembly are shagged, can I just replace them with Stainless, or Hi-Tens bolts and nuts?. The studs have a distinctive shaped head, but it looks like I could jam some aftermarket ones in there.

Looks like I may have to do a new rear sprocket, but do they give you new "bend-over" tabs for locking the sprockets nuts in place when you get a new rear sprocket?. Theres 3 of them, and mine are pretty rotten, I could restore them, but they would most likely fatigue when re-set.

[mazz1972]

Just to say you are doing an awesome job and I will be interested to see pics when it's finished. Well done!! :yes:

[kro]

Thanks Mazz.

I have done a little bit tonight, like polishing the rear hub thingy that the rear sprocket bolts onto, and slotting in all the new bearings, and prepping the rear wheel to be ready to paint.

I have done one frame mod, that I thought I would bore you all with, its a minor mod, but will create a major difference to the appearance of the bike. The little guard mounting tab on the rear grab rail drops down 30mm, and makes the rear guard sit down quite low, as is the way with the old DR's, but by cutting it off, and remaking a new tab that runs flush off the frame, and raises that particular mount point 30mm higher, making the guard raise up higher, and look a lot more motocrossy, and less agricultural :bleh:

See attached pic to see what the crap I am rabbitting on about.

[kro]

I am also replacing all mild steel bolts with stainless steel ones, and polishing the death out of them as I replace them. All fasteners bar the critical engine ones will be done this way. The effect is quite spectacular, as even the smallest change made has a big impact on the appearance of the bike. The ones holding the fork clamps in place look awesome, I will try take some close up pics to sow the change. The small details really make the difference.

[clint640]

Looking Good!

Be a bit careful about using stainless fasteners though. They fatigue & break pretty easy so don't use 'em for important stuff that might flex a bit like the subframe & footpeg mounts. See if you can get some cad-plated 8.8's instead.

Cheers
Clint

[kro]

Thanks Clint, I will only use em where they are appropriate, I am going to shove some aftermarket hi-tens ones on the new rear sprocket, I don't think my original ones can go another round, they are pretty far gone. I am just using the SS bolts for stuff like airbox mounts, fork clamps, and just general fastenings, and will make sure I use the right stuff on the critical points. Thanks again.

[kro]

Right, the weekend is upon us, I can hopefully pack some quality hours into this bike, and get a good quantity of progress pics ups, for those who are actually enjoying listening to me dribble about an old Suzuki. I am heading out in 5 to try find some new hi-tensile bolts for my rear sprocket.

[far queue]

... for those who are actually enjoying listening to me dribble about an old Suzuki ...Yep, keep up the good work, I'm enjoying the read.

[kro]

Ok, did more painting than anything, and you've already seen the pics of those items, I just final coated and clear coated some stuff.

1st pic is rear brake hub assembly, with freshly painted lever-arm.

2nd pic is the rear hub assembly, that normally has the sprocket attached to it, I had paint stipped it, and buffed it up a wee bit with my favouritest thing of all time... Autosol.

3rd pic is same thing again, but looking sexier again.

4th pic is complete hub assembly, with new wheel bearing, sprocket, 6 new 8.8 hi-tens bolts, with stainless washers, and nylock nuts.

Tomorrow should see some before and after photos of the swingarm, or at the very least, the shock, which is gonna buff up real nice, and I'm gonna be a cowboy, and paint the spring yellow, coz then it will look like an Ohlins unit, and the world will all say "oooh ahh, he has a quality shock on that bike", then I'll wake up in a sweat and realise I'm a sad bastard with an old slow bike.

[kro]

Update time, frame is now clear coated, and thus i may start bolting shit back onto it. As stated, this is a "poor mans resto'", so I made my own chain rollers, rather than spending 50 bux on shop ones.

1st pic, you can see the little blue chain rollers, all brand spanking new. I used ordinary old medium density polythene pipe, which is incredibly wear resistant, and cost me nothing.

2nd pic Is that a thing of beauty or what?.. 5 mins with the buffing wheel, and a smidgen of autosol, and whammo, you can see yourself in that bastard, it's that damn shiny.

3rd pic Rear wheel, with the rim and spoke nipples masked off, all painted and clear coated. This came up trumps imo, and I'm happy with the result.

4th pic Shock spring.... I wussed out on the yellow, simply because I was going to have too much colour in the bike, and yellow fades quick, and shows all the grease and gunk too easily. This is a very heavy duty enamel, and will be baked on, to make it extra tough.

More to come, but later this arvo

[Ghost Lemur]

Great work Kro.

What I need to know is how hard the strip down is? Really not liking my white frame, so weighing up some options. Pulling things apart is easy. Putting it all back together though, that scares me.

Took my first baby steps today and stripped off the plastics. Pulled the seat, and flipped the tank. Purpose was getting part numbers, but it was a good chance to look up close at different bits. Besides the engine pulling, the scarest part will be the electronics. Hell there not even a lot (for a modern bike) but still a worry as to how I'd get it back together.

It's got to be the one downside of going the way of a rare bike. No haynes manual.

Looking forward to seeing your rebuilt. If I can make a request it'd be lots and lots of pics and detailed step by step write up.

[kro]

To be honest Lemur, I am pretty rookie at this, the trail bike is a much easier beast to strip and rebuild than a road bike. I armed myself with a roll of masking tape, and a felt pen, and labelled everything as it came off the bike, so I knew what every nut. bolt, washer, and bracket did.

You'd be very very surprised just how quick you can pull a bike to bits, after the tank and seat come off, things just seem to fall off the bike so easy. If you are only going for a frame re-spray, that will be easy as pie to do, because you you can just take the front end off in one hit, then the swingarm in one hit, undo the CDI/electrics, and undo a couple of shock pivots/mounts, and you'll be damn near fully stripped to bare frame, it could be as quick as 30 mins all up.

I was shite scared of messing with the wiring, and all that jazz, but I unplugged 2 plugs, and took 2 ten mil bolts off the coil, and the electrics were done, and dangling in my hand.

[kro]

See if you can get some cad-plated 8.8's instead.

Suggestion noted, and acted on, new hi-tensile 8.8's on the bike as we speak. Thanks for the tip dude.

[kro]

How about Metalic Dark Grey, like the current DR's?

Suggestion noted, and used. I got the darkest grey I could, but couldn't get a metallic. The frame looks fantastic, although my shite-box digicam makes it look really light in colour, but it's actually quite dark. Thanks for the help in deciding on the colour.

[kro]

This is a great way to get my post count up, and get one of those flashy X things under my name, normally, I don't post alot, but my love of old suzuki metal has turned me into a regular post whore.

Here are 3 wheel shots, 1st is after painting, with all masking tape removed, 2nd and 3rd are assembled snapshots (minus brake drum on other side).
Bear in mind, I have not autosol'd the rims yet, or changed the tyres. The end effect, I believe, will be quite smart.

I still havent mastered this shitbox cheapo digicam, I keep getting blurry pics, sorray about that.

[kro]

What I might do is make a proper collage at the end of the whole things, and string all the pics into something resembling an order, and explain how I cleaned and prepped each part, what I used on it, that's of course, if anyone thinks it's worthwhile, someone has prolly already done this on KB I guess, so it's nothing new, and not a particularly exciting bike to showcase.

[kro]

I finally sold some shit on tardme, which will allow me to steam ahead with project DR alot quicker than expected. Below are 4 pics, of the front end, now re-attached to the grey bit.

1st pic WHOA, extreme close-up, get a load of that shine.

2nd, 3rd and 4th pic All pretty self explanatory, they are the bike version of porno for me, is what they are. I have lots and lots of photos, but won't bore you with all of them, as there is alot of the same thing taken from 5 degrees less angle than the previous one.

I was dubious about the blue anodising effect paint, but I think it's gonna pay off. Note the little blue valve caps on the fork tops. I have 2 more for the front and back wheel.

[far queue]

What I might do is make a proper collage at the end of the whole things, and string all the pics into something resembling an order, and explain how I cleaned and prepped each part, what I used on it, that's of course, if anyone thinks it's worthwhile, someone has prolly already done this on KB I guess, so it's nothing new, and not a particularly exciting bike to showcase.Just a thought, but if you're going to that trouble maybe Kiwi Rider would be interested in it for the magazine, they're always looking for contributions. Drop Ross a line, he could have a look at what you've done on here and tell you if he's interested. You never know there may be a dollar or two in it for you, and that'll make your rebuild even cheaper.

[kro]

Thanks matey. I will see if they are interested, it is only an old DR after all, but who knows, maybe they'll be keen from a VMX point of view. Is Ross on this website?, or do I chase him down thru kiwi-rider?.

[far queue]

Thanks matey. I will see if they are interested, it is only an old DR after all, but who knows, maybe they'll be keen from a VMX point of view. Is Ross on this website?, or do I chase him down thru kiwi-rider?.There's all sorts of riders reading the mag and they don't all ride flash new bikes. The techniques you've used can be used on any other bike as well, it's not about the bike you've worked on but what you've done to it, and the transformation you've achieved at low cost. So you push the storey from that angle, and the fact that it may provide the inspiration for others to do their bikes up too. You can contact Ross at editor@kiwirider.co.nz

[Percy]

Thanks matey. I will see if they are interested, it is only an old DR after all, but who knows, maybe they'll be keen from a VMX point of view. Is Ross on this website?, or do I chase him down thru kiwi-rider?.

It doesnt matter what the bike is man, if you do it right as you are, then its gonna look great at the end of the day!:rockon:

[PZR]

Just a thought on the chain rollers. I know you have already done them and they look great but another product to use is old skateboard wheels. Just a thought.

[kro]

Bloody great idea PZR, I should have thought of that.

Tomorrow should see a before and after swingarm picture or two, this is gonna be a real humdinger of a swingarm, you can see yourself in it.

[kro]

Sorry for lack of updates, more to come on the weekend. Been a bit crook, and been working on the swingarm, which is a freaking mission.

[kro]

Been trying to post pics all day, but the KB website has been poked.

Did a bit of re-assembly today, got the swingarm temporarily back in place, got the "A-arm" in, the shock pivot too, and polished everything, and even went to the bother of masking bolt heads off, to put that blue anodising paint in the bolt head recess (it cant get scraped), and generall scoured my fingers to the bone doing it.

[kro]

Some extra pics I felt like throwing in for good measure.

Shiny shiny alloy, that damn swingarm took me days to prep for polishing.

BTW, I would like to put a different muffler on the bike, the existing one is off some 70's Honda, and sounds OK, but it's pretty beat up. If anyone has a clean tidy muffler in their garage collecting dust, and would be happy to pass it onto me cheap, I will be very appreciative. I am watching a couple of tardme, but they always end up in the 100's, so I lose out. Yes, I am a charity case, but you never know till you ask.

[Ghost Lemur]

That's looking seriously mint DR.

[kro]

Thanks Lemur, there is seriously not one bolt, nut or washer that has not been polished/painted or replaced with stanless/hi-tens on this bike. Everything looks new, and she's gonna be a beaut when she's done. I am going to have to spend ages on that collage, it will be quite extensive. Kiwi rider never replied, I figure I killed off half their staff with excessive laughter..... "you're rebuilding a what ??!!!"....<laughter>

[cheese]

Maybe try DRD?

[kro]

I'm not that keen on having anything written about it really, it was a suggestion by Far Queue, which I followed up, just out of curiosity more than anything, so I won't pursue it any further. I have been made to promise the 3 major bike shops in Nelson, that I will take it to them the days it's finished, so they can have a good look at it, and it's going to have a truck load of photo's taken of her, so that will be enough me thinks.

All things going well, I should have the shock reassembled, and back in the bike tonight, so hopefully more photos to follow, later today.

[cheese]

you know you should get some old bikes, do them up like that and sell them. that bike looks better thana new one!

[kro]

My family would abandon me if I did that, thanks for the compliments though, I sorta feel a bit silly carrying on this thread, there seems to be very limited interest, and I feel like I keep saying "look at me!", I was just keen on sharing the experience, and some of the fun that goes with it is all.

[far queue]

... Kiwi rider never replied, I figure I killed off half their staff with excessive laughter..... "you're rebuilding a what ??!!!"....<laughter> Oh well, it was worth a shot, at least you know now and don't need to wonder what if.


... I sorta feel a bit silly carrying on this thread, there seems to be very limited interest, and I feel like I keep saying "look at me!", I was just keen on sharing the experience, and some of the fun that goes with it is all.No, carry on. I'm impressed with the effort you've put in and the results so far and want to see the end result.

[cheese]

Ah with 865 view I tihnk there is a fair bit on interest.

Keep it up!!

[kro]

Ok, at least of a couple of you guys are watching it, I'll keep going. Shock is polished/painted reassembled. Photos of that by itself tomorrow, then picks of shock installed, along with the shock pivot, and A-arm all attached etc etc. I spent $7.90 on the bike today, and got new Hi-tens bolts for the footpegs, new Hi-tens fork top clamp bolts, a dozen or so SS spring washers, and 10 odd SS flat washers, and a dozen nylock nuts in varying sizes....... i love trade discounts !!

Found my "missing" bottom clip that holds the fork covers on, I thought I had lost the damn thing. Gonna have to get new brake and clutch cables, mine are roo-ted, they about 70 bux for the pair. Was kinda hoping I could salvage the front brake one, and keep costs down, but the cables frayed at the lever end.

[cheese]

yeah I just got busted spending $160 on a memory card so I'm in the dog box.

[NordieBoy]

Either tell your camera not to put the date/time on the pics or set the date/time correctly :D


"Kiwi Rider: There's this weirdo who did up a DR 4 years ago and want's us to put it in the mag now"

[kro]

I tried, but it won't hold the date, it seems to reset when I change the batts. I have reset it, I'll wait and see if it fixes itself.
Nordie, you have a good camera, I was going to ask if you would mind taking a few snaps of it once its complete please.

[Ghost Lemur]

Waiting on the pics.

Sounds like it's coming along swimmingly.

[kro]

The pics are coming, but only of the shock, I will be snapping some pics of it in the bike tomorrow, I lost my light, and have no flash.

[kro]

Here it is, I did the best I could with it, but she's pretty old, and has a lot of pitting in the alloy, but I managed to get a shiner out of it.

[cheese]

You have to take a pic after your first ride when you get it all muddy as fuck. LOL!!!!!!!!!!!

Looking mint!

What do you use to polish it? Autosol and a buffer wheel? I might hit my rims with a dremmel and polishing wheel.

[kro]

If you do, my advice is to check for clear coating on the rims first, if you have clear coating or excessive oxidising, you need to cut that back with a fine wet and dry for oxide, and paint stripper for clear coat. Best to remove the tyres if you do paint stripper, as some brands arent good on rubber.

A cloth buffing wheel is easy to make, once the stripping is done, autosol the death out of them.

I got the shock in tonight, and got the shock reservoir mounted in its correct posistion, I had it mounted in the wrong place this whole time, but it was like that when I got it, and didnt know any better, but I found some original pics of a DR, and saw the reservoir mounted up the back of the bike, so I then discovered what the two little holes up the back of the frame were for, I always wondered what they did, now I know.

Should have the front wheel on tomorrow too. Pics to follow tomorrow.

[kro]

Lots of shiny new bolts, and bits. I'll shut up, and let the pics do the talking. For those that have been following this, I have started resizing the photo's to a lower res', that will mean they open faster for you dial up users.

[kro]

more pics here

[kro]

and last of all......

[far queue]

Lookin' good - it is going to be a shame to get it all dirty after all that painting an polishing. Are you going to the Nelson rally in November? I'm curious to see it in the flesh.

[kro]

If it lasts that long, yes I will have a serious look at going, or if I am unable to make it, I can arrange a private viewing.

[Ghost Lemur]

Question for you Kro (and those of you who have been following this thread).

We all know you've polished the beejeebus out of that baby. But have you done anything in order to minimise the effort to maintain the look? Is it clearcoated, or do you have a plan as to maintainence?

If not, what are the options? As one who is following this closely with the plan of doing something similar with my baby. But as we're planning on getting these things dirty, the ability to maintain the look is important.

[kro]

My experience with autosol is that it does also coat the metal with a protective coating, and although it is not a hard wearing coating, a small amount of maintenance will bring the shine back with minimal effort. I actually tried to avoid clear coating major parts like forks and swingarm after polishing, because if you get a patch of wear thru the clear coat, the alloy beneath will start oxidising, while the rest looks mint, and to rememdy that means a full strip down before even thinking about buffing it up again.

I have heard of some people adding silicone spray to the finish, but I think more to give a shine, and make cleaning easier after rides, as stops dirt sticking to alot of surfaces.

[barty5]

i spray silicone on mine depending on where we are riding dose help with cleaning not so much on long muddy rides though get worn off dran quick
(make bike look wicked for 1st 5 - 10 min) i write it of thrugh work so not bothered by cost of it

[kro]

Going shopping for new levers tomorrow, and to pick up my new front brake cable. Will post pics of the finished handlebar assembly tomorrow too. I purchased new progrip 793 handgrips off tardme, 18 bux, and they are grey and blue, like the bike, so they should arrive next week.

[kro]

I finally got the wheels on the old girl, and the sidestand, and a few other bits.
More pics tomorrow.

[far queue]

That last pic looks cool - mint

[cheese]

Now you just need some new tyres...... lol

[kro]

I have some, Finn gave me a new 21' front, and I found a cheapo 17 ' rear brand new, for 65, so I'm gonna splash out and get it. I found out my existing rear is really quite too wide for the bike, and although will give me a good amount of grip, it will be robbing me of a good amount of power too.

[Sketchy_Racer]

Thats amazing Kro!!!

I must do this to my old battered KDX one day!!!!!!

[Coyote]

My family would abandon me if I did that, thanks for the compliments though, I sorta feel a bit silly carrying on this thread, there seems to be very limited interest, and I feel like I keep saying "look at me!", I was just keen on sharing the experience, and some of the fun that goes with it is all.
I've only just noticed this thread today. I'm surprised I never saw this thread before. I've read it from the start and it's been great. I'd love to do something like this once I get a suitable bike (which may be soon). Project: Black Hole :D

If KR aren't interested (but I'm sure they would be), VMX will certainly be interested

[kro]

Thats Coyote. I have my eye on some new plastics, I was kinda hoping to go white, I will probably be getting the tank resprayed white (original colour), and the rest of the colours on the bike would suit white more than yellow which it had originally.

I am still going to do a collage of the project, along with all materials used, and methods used to do it with, I won't have that complete for some time though.

On a different note, I am not posting again until tomorrow, because then my post count will match the day, and we all know what day that is....... CONSPIRACY.. !!!!!!

[far queue]

On a different note, I am not posting again until tomorrow, because then my post count will match the day, and we all know what day that is.......Ummm 11/9/06, I don't buy into that american bullshit - their spelling, and their date system and so on - I guess you'll have to wait a bit before you reply :shutup: :bleh: :devil2:

[kro]

Yeah true, screw that, I wanna get one of those flashy X things to prove I'm a post-whore.

[kro]

I received an email from a man at VMX New Zealand, and he is keen to put the story of the mighty DR on the VMX website. This will be quite a good shot in the arm for the whole project. Now I have to get my thinking cap on, and write a bit more about what I have actually done.

[kro]

No update sorry folks, been spending time with the family, to make up for my motorcycle induced hermit behaviour.
Tomorrow perhaps we may see a bit of a mock up of tank/seat/sidecovers on the old girl, but i wont look to good, coz the old plastics don't look good on the bike now that i have added that anodising blue colour to the front fork clamps.

I am sizing up some white aftermarket plastics, they will look awesome.

[kro]

MIGHT have just found the top end I need to make this damn bike run at the end of this project. I have to wait for it to come out of Wellington, but should get it by the end of the week. Getting some white plastics for it, hopefully I can modify them to fit, they are off a YZ.

Updates coming again soon.

[Coyote]

I've been doing a bit of restoration myself. Plastic welded the front fairing back together with a soldering iron and an ice cream container lid. It's not visually pleasing but it's solid enough for racing :D

[kro]

That's often all that is needed mate, if you nneded to take it a step further, you could have used a bit of filler in the crack area, and sanded it, and painted it, noone would be any the wiser.

I am finding myself in more and more situations where I need to fix stuff up myself, as opposed to when we were a 2 income family, I'd take my bike into the shop, and say "fix this", but now I have to be a bit wiser with every penny, so I do things like the ice cream lid weld, which I did the same thing to on my airbox, which had lots of extra holes drilled in it for extra air intake capacity, I've sealed all but one of them off, using the soldering iron/piece of scrap plastic method, and I'll paint the whole thing, and she'll be beauty.

[Ghost Lemur]

Loving the work Kro, keep it coming.

[kro]

Thanks Lemur, I just painted the footpegs, and rear brake levers/arms, and have them baking in the oven right now. Hopefully some pics tomorrow, there's been a bit of a drought of updates sorry guys, I will deliver the goods tomorrow.

[Ghost Lemur]

Baking??

Details please.

[kro]

Duplicolour Hi-Heat paint. Resists temps up to 1200 degrees, and leaves a very very hard durable finish, but you have to "bake" the paint on in order for it to dry properly. I am doing the exhaust in it, and the footpegs, and brake/gear levers, seeing as they get a truckload of wear on them, the paint is extremely wear resistant. Just chuck the bits in the oven for 20 mins at a certain temp (it's stated on the can), and you have a sweet looking finish, that's extremely durable.
You can hang the parts over a gas heater too, to get the baking done.
Its only like 15 bux a tin from Repco.

[timmy]

This is a really interesting thread Kro. I bet it very satifying doing all the work yourself. Have you been a bike mechanic in the past or just know what you know from riding the bikes?

(sorry you could have already stated this in the thread but i cant remember)

[Ghost Lemur]

How does that paint compare with anodizing and powder coating?

By compare I mean across all the categories, finish, durability, cost, look and maintenance?

[kro]

Timmy, I am not a mechanic, but am reasnably mechanically minded, and have been fixing cars and bikes since I was 15 or so.

Lemur, I haven't tested the durability of the paint, but anodising is still the best option, as it is not a "coating" in the traditional sense, like paint is, the paint, given enough aggravation, will still scrape and chip I think, hence whey I used it in places less likely to get bashed.

[kro]

Ok, I just chucked all the old plastics on, and wheeled it out for a quick photo or two. Note the sexy new 3 finger brake lever assembly. The bike is most likely going to have white plastics in the end, because as you can see, the blue shit I used on the forkclamps looks a bit flowery next to the yellow plastics.

[kro]

The post I made a few pages back about have the rear guard mount chopped off, and re-welded about 30 mm higher, so it runs straight off the frame has resulted in the desired effect of raising the overall guard height up, as you can see in the side views. I just have to wait and see how the new plastics I have got, will modify to the old girl.

[cooneyr]

Bikes looking great Kro. I've been watching since the beginning and seeing how you are getting on. The old beast is gona look better than new by the time your finished. If it was me I'd fear ruinning all the work by riding it - glad that you dont. Keep up the great work.

Cheers
R

[WRT]

Its a fantastic effort you have put in here Kro, the bike is coming along beautifully. Have you any plans at this stage for the seat? The one on my old XT use to leak, so I wound up stripping off the material and stretching some black vinyl over it by hand (with the old man giving me a hand to hold it in place). Stapled it underneath and it came up looking great. This was years ago, so cant remember the cost, but it was basically next to nothing, and it made the seat look as good as new.

[cheese]

I can hook you up with seat covers.

[kro]

Bikes looking great Kro. I've been watching since the beginning and seeing how you are getting on. The old beast is gona look better than new by the time your finished. If it was me I'd fear ruinning all the work by riding it - glad that you dont. Keep up the great work.

Cheers
R

Thanks matey, it's my only bike, so I am sorta limited in what I can choose to ride, so the old girl is gonna have to get muddy again. I might take it to the Nth vs Sth in Havelock, I will see when the time comes.

[kro]

Its a fantastic effort you have put in here Kro, the bike is coming along beautifully. Have you any plans at this stage for the seat? The one on my old XT use to leak, so I wound up stripping off the material and stretching some black vinyl over it by hand (with the old man giving me a hand to hold it in place). Stapled it underneath and it came up looking great. This was years ago, so cant remember the cost, but it was basically next to nothing, and it made the seat look as good as new.

Thanks to you too, I have appreciated peoples feedback, and suggestions, a couple of which I have used on the bike. As for the seat, it will be recovered, and I am most likely going to do it black, or black/yellow, like the mid 90's DR350's. If i run out of dough, I will use your method, I had thought of something along those lines, and it's nice to know someone else has done it too.
I am off to work on the old girl now.

[kro]

I can hook you up with seat covers.

PM me with details please, just to keep my options open. Thanks for your reply too.

[kro]

With the help of a very talented man, who is also rather generous, I have some webspace, with a whole heap of the Project DR pics thumbnailed, that are basically in the order that the bike has been restored in. I have downsized all the pics to a lower resolution, so that dial up users can get into it, and not be slowed down by huge images.

http://kro.nzfortress.co.nz/filebrowser/index.php

[kro]

Arriving tomorrow should be a new set of hand grips, which are blue and grey, which will compliment the colours on the bike very very well, and also, I should get a set of plastics (new), which i was hoping to be able to modify to fit. The plastics are white, but there is only 2 sidcovers, and a rear guard, so i will still need a front guard, and number plate, but they will be a piece of cake to get.

The set of grips at the front of this row, are the ones I'm getting (blue/grey)
http://www.mxdirtrider.com/h-products/pr-bodyparts-control-handgrips-progrip-793.htm

[Coyote]

Haha, I got some of those progrips for my bicycle a while back :D They're really comfy with bare hands. They look pretty abused now with the bike being dropped on it's side several times but otherwise they've held together really well. I've got some road bike progrips for my other bicycle too

Just looked through Repco after school (half day) and saw the Dupli-Color Metalcast paint cans. I got a can of red, more of an impulse buy than a planned purchase but it'll definately be used. And I've noticed on the can it says 'heat resistant up to 500 degrees F' and you can get an undercoat for non-shiny surfaces. So is it possible to paint an engine? I was thinking on the second RG I'm getting to paint the engine matt black with anodised red highlights (like the head of the cylinder)

If no one knows, guess I'll be the first to find out :p

[Ivan]

Na youll beable to paint it




Looking good to Kro I just am in the stages of making my DR 350 real nice just got new fork oil for it to put in rear shocks so I can do the MX meet in a few weeks

What are you doing for a exhaust system run the standered one or run a aftermarket muffler, I have a DR350 with a CRF250 header pipe madeof titanium gets quite hot by ya leg and a FMF Powercore 4 Muffler sounds like a beast

[kro]

Nice work Ivan, I was gonna ask if you had started working on your DR.

[Ivan]

Nice work Ivan, I was gonna ask if you had started working on your DR.

Cheers, Its had its pulse coil damaged tho so I am on the look for a new one was going to check around here for one the flywheel or something has hit it and bent it and i have straightened it but is still quite damaged it will not kickstart at all you have to run in 3rd gear and jump on the seat and then it fires up

It has had the head ported exhaust system changed weisco high comp 385 piston after market plastics etc is a nice bike think I am going to have to oil cool it as well

[kro]

Sorry bout lack of updates, I have had a monu-freaking-mental family crisis to deal with, and it's far from over. I was hoping to steal some time on the weekend, and might post pics then.

[Ghost Lemur]

Naughty family, don't they know you have a bike project on the go. Very rude.

Hope alls well and looking forward to the update Kro.

[kro]

This is roughly where I'm heading with the plastics,. These are off a YZ250 around the 2000 mark, or so I was told, but they are brand spanking new, and I got all 3 for 30 bux, so I was stoooooked.

I will be getting the tank repainted in the same colour, as I will always be putting white replacement plastics on it.

[Coyote]

Haha, that looks wicked! My Dad and brother agree too

[cheese]

Mate you should just fit an RMZ motor to it now!!!

Looking mint!

[kro]

Thanks guys, I am still on the hunt for a top end. If anyone knows of a cheap GN/DR top end, I am still needing. I bought a spare engine for 75 bux, but the top end was shagged.

[Ghost Lemur]

Looking good as always Kro.

Takes guts to go with white panels. I know for the few pieces on my bike that it's pretty much impossible to keep them clean and they show up every mark.

Did you ever consider something like a gunmetal grey (like the image in your sig). Was really hoping you were going to do some plastics painting so I could watch and learn.

[barty5]

check out this auction number just cut and paste in ebay search 200014889385 this is for a head he also has shit loads of other parts all from a 1982 and is happy to ship world wide has buy know of $49.99 US may pay to check cond 1st

[kro]

Thanks Barty, I messaged this guy, and he reckons it was from a good runner, so I may end up getting the top end from the States, who would have guessed eh?.

[cheese]

I've been really happy with all the bits of gotten from teh states of ebay. So far I've gotten

cyclinder inculding power valve
swingarm
linkages
FMF Fat boy expansion chamber and muffler
seat holder thingies
complete clutch

and all of that cost me around $800 nzd and all in really good condition.

Now I just got to find me some radiators, well just a left side one.

[kro]

Sorry, Project DR has stalled until I can raise more funds for the old girl, and find a cylinder head. I'll ressurect the thread once that happens. I just had to shell out "bike" money on emergency plane tickets for my family, so that's kinda forked things up for me in the mean time. I promise I will finish this, the simple fact of the matter is that I have to, it's my only damn bike.

[far queue]

Do you think you'll have it finished by the time of the Maitai rally (4/11)? I wouldn't mind seeing the finished result after following the project.

[kro]

I'd love to have it finished by then, but I cannot make any promises sorry Q.
I'll keep in touch though, you could at least drop round for a coffee on your way through, and see wher it's up to. I would love to have it finished in the next couple of weeks, but I think that's stretching it.

[kro]

Should be getting the seat re-covered Monday, I think I'll get it done in plain black, but if they have a nice dark blue, I might consider it. Once I get that done, I will be able to get the plastics mounted properly.

Tank still needs painting, might be getting that done end of the week (ish).

I took my brothers KLX up into the forest today, had a great ride, but I was shattered after just 3 hours in the saddle, when we normally stay up there for about twice that.

[kro]

Spam post to get me over the thou mark

[kro]

Now im a Ducati @ 999 ....woohooo

[far queue]

Come on then, get it over with, you know you want to be a whore - forum whore that is :whistle:

[kro]

I wasted my thousandth post in the online trading section, but having said that, I nice chap called Turtle may have found me the engine bits I need.

I will have a couple of pics of the newly recovered seat hopefully this afternoon, depending on whether my upholsterer lets me down.

I have found a DR 250 motor on trademe, that I have a good chance of winning, and it's in Taupo, which is a bonus, as my company has a branch in Taupo. Either way, I have a good chance of landing the bits i need to make Project DR a done deal.

[insane1]

very good sounds like this will be a good build keep us informed of your progress.

[far queue]

I have found a DR 250 motor on trademe, that I have a good chance of winning, and it's in Taupo, which is a bonus, as my company has a branch in Taupo. Either way, I have a good chance of landing the bits i need to make Project DR a done deal.Excellent. 2.5 weeks untill the Maitai Rally - no pressure :whistle:

[kro]

LOL Q, I am hoping buddy, I really am.

I got my seat back today, it looks awesome. I got home too late to take photoss though, so I'll do that tomorrow for yall.

[kro]

Recovered seat, and attached rear guard, with sidecovers just tacked on roughly where I think they should go.

I'm watching a complete running motor on tardMe, and am hoping to win that auction, as it will fast -track the finishing of the bike then.

[kro]

Repainted and repaired airbox. The airbox was heavily "modified" by previous owner, and had 3 extra air inlets, which all had various hoses coming out of them. I have cut this down to the original, and one extra, which I could not plug successfully, due to inaccesability of the hole on the inside of the airbox.
I used some of the offcuts off the modified rear guard to melt in place with a soldering iron, to patch the extra holes, and make the airbox alot more water resistant than it was.

The airbox side cover needed repairing, which was basically soldering iron style plastic "welding" again.

Obviously that last pic is the cover that goes on the left had side, over the front sprocket, which traps enough clay to make a pottery vase with, but it looks pretty , so it's going back on the bike.

[kro]

2 mins ago, I won an auction for a complete DR250 motor, that is a runner, with an exhaust system and carb, for 100 bux, there is hope for the completion of Project DR yet. I will keep you posted.

Turtle, I will be in touch about the bike you told me about, I will work out the finances, and let you know.

[barty5]

I was watching glad you won the aucton

[kro]

Haha, the funny thing is, the guy who I went into a bidding war with, is a guy I have dealt with on trademe before, and is a real good sort, and seems to have quite a collection of running DR's, and he only wanted the CDI out of it, and has offered to buy it off me already, so that's reduced the cost of the motor dramatically already. I won it for $106.00, and he's giving me $50.00 for the CDI/Ignition system, so it's one cheap motor, and it has an exhaust system and carby too.... I can't lose.

[Ghost Lemur]

Exellent work kro.

You're an inspiration to those of us with minimal bike budgets.

[kro]

Thank you Mr Lemur, your encouragement spurs me onward.

[far queue]

Thank you Mr Lemur, your encouragement spurs me onward.9 sleeps till the rally :whistle:

[kro]

Hehe, even if the DR isn't finished, I might be able to go over the Maungatapu with you on one of my brothers bikes, I'll pm you my contact details, so you can at least see the mighty DR on your way thru if it's not fully back to together.

[Turtle]

2 mins ago, I won an auction for a complete DR250 motor, that is a runner, with an exhaust system and carb, for 100 bux, there is hope for the completion of Project DR yet. I will keep you posted.

Turtle, I will be in touch about the bike you told me about, I will work out the finances, and let you know.

sweet as...I was watchin the auction..Good on ya.An hope the top ends all good.Depending on what you decide my mate would be keen on buying the righthand eng side cover if yr keen on selling it.Keep in touch.

[kro]

Turtle, is he still selling that DR we spoke about, or is he going to try get it going again?. I have another engine here, with good sidecovers on it that I might be convinced to sell.

[Turtle]

Turtle, is he still selling that DR we spoke about, or is he going to try get it going again?. I have another engine here, with good sidecovers on it that I might be convinced to sell.

Hes unsure...has lost interest in it...so would sell around 3 hundy

[kro]

Been a bit under the weather the last couple of days, but did this today.

Basically I have re attached the accel cable, added another new clutch lever, the same as the brake one. Chucked on a brand new front guard, and brand new number plate. I out the new handgrips on, and cross bar on the handlebars. The last major stuff is really putting the engine back in, which should happen next week, so long as no big disasters strike. Later on today, I will put the front brake cable back on, which is also a brand spanking new item, so it will keep the bike looking sparkly fresh and new.

Enjoy.

[far queue]

It's looking great, especially compared to the that dirty thing on page 1 of this story. Have you got some pics of the complete bike before this restoration started?

[kro]

Yes, I have lots of pics of the complete bike prior to strip down. I think its looking pretty damn fine for a 24 yr old clunker.

[kro]

Maybe, just maybe, tomorrow, my tardme engine arrives. I am going to jam that sucker straight into the bike, and see if I can get it to fire up. If it does..... good times are coming......

[timmy]

Man you will be looking forward to that. I hope it all goes well for getting it going

[NordieBoy]

You might jam the engine in there but...

How long before it's back out and getting polished?

:D

[Ghost Lemur]

You might jam the engine in there but...

How long before it's back out and getting polished?

:D

I would have thought with the amount of time and effort he's put into the frame etc, last thing he'd be wanting to do is throw in a crusty engine.

Come on kro you know it's true. The engine will arrive, be striped. Every piece made to sparkle, ensured to be the the best possible condition before being reassemble. Then and only then will it deserve to be sitting in that bike.

[kro]

Of course....... I only want the engine in there, so I can fire it up safely, then it's coming straight out, to get stripped and polished. I aint no savage !!!!!!! (mostly). You are right, I have come to far with this to just chuck some crusty looking powerplant in there. The tardme engine will be used whilst I revamp the other engine I have, so eventually, I will have 2 good engines for it.

Today's the day, well, it bloody well better be, I have waited what seems like eons for this engine.

[NordieBoy]

I waited 2 months to get my TradeMe engine :) (The guy went overseas, told his dad about the engine sale but took his shed keys with him).

But then again I've got a frame and a pile of other bits on a pallet in Wellington I've been waiting 18 months for :rolleyes:

[CM2005]

Wow!!:gob: Thats an awesome job you've done. Looks quite professional actually! I'm thinking of trying something similar with this '89 CR125 I've just got, but no to that extent.. Keep it up!:rockon:

[kro]

The engine arrived, the bulk of it is shagged, but the one piece I have needed the most, seems to be in OK nick, and might get me going for 6 more months while I get my original head renewed.

The engine I got, had the front sprocket welded on, the gear shift spline was bent at a hell of an angle, the clutch basket had chernobyled at some stage, and there are aluminium chunks all through the engine as a result. Several clutch plates are broken, and rings were in several pieces, and the piston has gouges in it. The engine had a hard life. There was no oil in it, and a fair bit of water in the cylinder.

All this aside, the top end for some reason, has weathered the storm, and like I said, will tide me over, until I can get my original head and cam rebuilt. The electrical system is intact, so that's a bonus.

[cheese]

Fucking hell! What a disaster!! Man some people will just sell shit on trademe on do you over. Lucky the bits you need were ok!!!

[kro]

I will make all my money back on this engine over the next 2 weeks, so I'm not too upset. The top end is just OK, and barely anything more, but with the way I am at the moment, I just want a finished, working bike dammit !!!!!.

Thanks for all your encouragement so far troops. It's been a long road, longer than it should have been imo, but we are near the end now.

[kro]

Slightly off topic, but I met Far Queue today, damn nice chap, and he got to see the DR in the flesh, while I drooled at his 650.

I worked the first half of the day today, and of all bloody things to happen, a guy pulls into work wanting some pipes for a drainlaying job, and lo and behold, he has a 1982 DR250 S on his trailer, needless to say, he didn't get away for a good three quarters of an hour, while I told him what parts I had from my spares bins that he needed, and we generally talked bikes till the cows came home, which they did, and happy cows they were too.

I have formed a little network of DR afficianados, from as far afield as Levin, and Napier, to Chch, and one more today in the form of a KB member who just so happens to live in little old Nelson whom Far Queue told me about.

Anyhow, its dinner and beer time, tis been a long day.

[Ivan]

im a dr guy to, heres a pic of myne nothing serious just abit of fun riding

[kro]

Droooool, I want it !!!!!. That's what I want to end up with eventually Ivan, is a DR350. Nice bike matey.

[Ghost Lemur]

Where about was the pic taken Ivan? Looks like a cool area.

[Ivan]

its lake wairarapa in featherston the sand track is awsome fun I crashed it today and my throttle cables snapped so im now on a hunt for some new cables

[NordieBoy]

And if it was running you would have had a real blast over at the Lower Wangapeka laidback today :D

[pervert]

I haven't read this whole novel, so someone may have already made this clear...but...

If you had spent even half the time you have spent on here talking about/itemising your project...working on your project instead...you'd be long finished by now...

[Ghost Lemur]

I haven't read this whole novel, so someone may have already made this clear...but...

If you had spent even half the time you have spent on here talking about/itemising your project...working on your project instead...you'd be long finished by now...

What a crock of shit.

Kro has done a fantastic job and has been an inspiration as to what can be done. Projects take time, parts sourced. Waiting is part of the nature of the beast that is a project. If anything I'm sure having this thread and knowing that there are those of us who are gaining valuable knowledge from what Kro's doing has helped keep the motivation up at those points where projects can often find themselves on the back burner.

I suggest if you want to play a constructive part in this thread you actually go back a read the whole thread.

[pervert]

I suggest if you want to play a constructive part in this thread you actually go back a read the whole thread.

Haha let's not get carried away...

He spent $6.00 on degreaser...:whocares:

[kro]

And if it was running you would have had a real blast over at the Lower Wangapeka laidback today :D

Quiet scum-bum, I'm waiting for parts to come, which are taking longer than expected, and also, money is a major factor. I'll get there dude, it's just taking time, this thread keeps me from flipping out, and rage-quitting the whole idea.

Pervert, If I was a wealthy man, I could have finished this weeks ago, or even purchased a couple of new bikes, but I'm not, so I persevere with my little old DR, and wait till I get enough money to complete the next stage. It's teaching me patience if nothing else.

[barty5]

dont stress pervert rides a pit bike and profile shows a shitty old quad how long it take you to prop it up for the photo looser this project rocks has got me doin full work over on gsxr i bought was to be a quick do er uper but doing it properly now

[pervert]

dont stress pervert rides a pit bike and profile shows a shitty old quad how long it take you to prop it up for the photo looser this project rocks has got me doin full work over on gsxr i bought was to be a quick do er uper but doing it properly now

Haha ouch...and no propping was involved, check the stunting section for the video if you don't believe me...:done:

By the way, looser is spelt loser, loser!

[pervert]

Pervert, If I was a wealthy man, I could have finished this weeks ago, or even purchased a couple of new bikes, but I'm not, so I persevere with my little old DR, and wait till I get enough money to complete the next stage. It's teaching me patience if nothing else.

Fair enough, good luck with it.

[Ivan]

kro deserves the name the dr he is doing the job properly and im in full support and a kro fan

[kro]

Thanks troops.

I have just got a small cash injection, which should help finish off the bike in a week or so. Fingers crossed.

[Ivan]

sweet kro i cant wait for finsihed product i just went and worked on myne before making it nice and reliable

[far queue]

Slightly off topic, but I met Far Queue today, damn nice chap, and he got to see the DR in the flesh, while I drooled at his 650.Great to meet you Kro and see the DR in the flesh, you've done a great job there. It's certainly a labour of love, well done mate. I passed on your details, so you'll probably have another visitor sometime some if you haven't had already.

[Wellyman]

Updates, Updates please Mr Kro! But an enjoying the progress so far..
pervet if you dont have anything relevant to Kro's project, fuck off, this is some really challenging work he is doing, I know as I have rebuilt a bike from scratch before.
WM

[kro]

Updates are coming, I am just waiting on baited breath for this money, which should be here tomorrow.

I am having a blast selling DR engine parts on trademe, I got sick of looking at the two dud engines I bought, so I started stripping them, and found they had some good saleable stuff on them, and I have sold some of the parts already. I might just make my money back on them, which im very pleased about.

One question for the mechanics out there. How the heck does one remove the flywheel on a DR 250?. I got the nut off, but then what do I do? is it on a left hand thread, or is it a gear puller job or what?. I don't want to bugger it, and break the magnets.

[far queue]

pervet if you dont have anything relevant to Kro's project, fuck off ...Hahahahaha, excellent, succinct, and to the point, and I heartily agree :rockon:

[Sketchy_Racer]

Kro,

Nice job on the bike man. Very good effort.

RE: the flywheel. You will more than likely need a flywheel puller. You can -Sometimes- get them off with a hammer, but you need to be prepared to wreck the flywheel, which you don't want to do.

-RG

[kro]

Thanks RG100, I wondered if it was a specialised tool job.

Good to see you home safe there FQ, you missed the weather perfectly, it's been HOSING down here for the last 2 days, absolutely miserable matey.

[far queue]

Good to see you home safe there FQ, you missed the weather perfectly, it's been HOSING down here for the last 2 days, absolutely miserable matey.I'm pleased I missed that then, my tent was pitched in a hollow at the rally - I wondered if it was a wise move as I was putting it up. I guess, I got lucky.

[Ivan]

Thanks RG100, I wondered if it was a specialised tool job.

Good to see you home safe there FQ, you missed the weather perfectly, it's been HOSING down here for the last 2 days, absolutely miserable matey.

you shouldnt ever hit it as you can damage the crank as well i make my own specilized tools to do the job

As sometimes you cant get a bit to fit flywheel puller

[cheese]

I got a flywheel puller for $20 from super cheap auto.

[kro]

Thanks cheese, I'm off to Supersheep tomorrow, for my own puller. That sounds a bit rude doesn't it?.

[cheese]

ha ha ha

My puller was too big for teh hole!!

WRT got one the same and grinded it down a bit to fit.

[kro]

Right, I have scoped out another whole DR 250 on tardme, with a complete spare engine, and the engine in the bike supposedly rebuilt. I will bid on this tomorrow, and see if I can swing it, and if I can, by Friday next week, I should have the DR damn near finished.

I'm going riding with my brother today.
1 x KLX300R
1 x KX250

The green team !!!!!!!

[NordieBoy]

So did you get blown away by the power and handling of the tuned 250? :D

[kro]

It's pretty scary tbh, I can't honestly say i would enjoy riding a 2 smoker, the power just comes on so hard, and so fast, which is sooooo not my riding ability or style. It's fantastic for a bit of a blast, doing wheelies in 3rd on the power, but man....... it's hard work.

Hopefully the mighty DR is reborn in the next week or so, and I can get back to riding like a Nana.

[NordieBoy]

You should have seen Shane throwing it around during the Pony Express race at the North v South.
He was 1/2 a lap behind a 125 2-smoke and caught him at the end of his 2 laps.
As he went around the first corner you could tell he was giving it everything and he'd either catch him or ride home in the ambulance :D
He was quite pleased he could hold out Brad Thomas on his RM400 for a few laps as well.

[kro]

Yeah, I bumped into Shane on Sunday on his Husky, and he gave me a quick run down, it sounded great.


I just just purchased another whole DR250, with 2 motors, one of which is a runner. This means two electrical systems too, which means I will most likely start a new fix up thread for the second DR. The bike is in New Plymouth, so I won't see it till next week some time, but it should see the DR finally finished, but a new project begin with the whole spare bike I will be getting. Oh great they cried, another shitbox DR fix up thread....... woohoo.

I got the whole lot for 240 bux, which as I said, is a whole bike with a rebuilt motor, and a spare motor. I laughed when i saw the picture on trademe, the front wheel was on the wrong way, and turned 180 degrees as well.

So, to summarise, DR to be finished the weekend of the 25th Nov, but new DR thread to emerge as well. I will do things a bit differently on the next DR though.

[Ghost Lemur]

Great news Kro.

Looking forward to seeing the finished product.

What sort of things are you looking at doing different? It's a slippery slope you know now that you've got the project bike bug.

Talking of which I saw this (http://www.trademe.co.nz/Trade-Me-Motors/Motorbikes/Motorbikes/Dirt-bikes/auction-77096301.htm) on TradeMe. It's even in my city. Would make a great project and would be a fun ride for when the sons get their first motorcycles and I can take them out to the forrest. The CRM really doesn't like puttering at <10kph, it finds it humiliating.

*I must not buy*I must not buy*I must not buy*

[kro]

That beta would be cool Lemur, but I know what you mean, you have to show some restraint, less you wind up with a garage full of hardware. Hang on, what's the problem with that?.....

The things I will do differently on the next DR, is to not drag the damn project out so long, and to maybe not get so anal about some of the smaller things, but having said that, I am pretty anal (just ask zerax), and I can see me getting carried away again.

This will take the bike count to 5 in my 2 car garage, and the engine count to 8, 5 of which will be DR engines.

[Ghost Lemur]

That beta would be cool Lemur, but I know what you mean, you have to show some restraint, less you wind up with a garage full of hardware. Hang on, what's the problem with that?.....

The things I will do differently on the next DR, is to not drag the damn project out so long, and to maybe not get so anal about some of the smaller things, but having said that, I am pretty anal (just ask zerax), and I can see me getting carried away again.

This will take the bike count to 5 in my 2 car garage, and the engine count to 8, 5 of which will be DR engines.

And how many of those are running? :dodge:

[kro]

Err, none of the 3 engines I have now would run for more than 1 month without dieing of death rattle disease. This however will change, like my underpants.

[NordieBoy]

Your undies die of death rattling disease?

:confused:

[Wellyman]

Anoooother DR project to come, awsome nws, but lets see the finished first bike, before we get ahead of ourselves.
keep up the good work.
WM

[Coyote]

I've paid for half of Jamezo's bike. Hopefully I'll be able to bring it home soon and start stripping it down :D

[kro]

Your undies die of death rattling disease?

:confused:

My undies are a forensic scientist's wet dream, the rattling is just the icing on the cake so to speak.

[Ivan]

hey guys at least kros got somewere in 15 pages in mynei am up to 48 I think and the bike is still the same as it was 12 months ago

[kro]

Freightlines uplifted the DR in N Plymouth today, I will probably see it Monday ish, so expect a big rant, either good or bad, around the Monday Tuesday time slot. It's a bastard, I have to goto Chch thur/fri next week, so I'll lose those days.....poos

[kro]

hey guys at least kros got somewere in 15 pages in mynei am up to 48 I think and the bike is still the same as it was 12 months ago

You have a fix up thread?...... show me !!!!!!!!!!!!!!

[Sketchy_Racer]

Kro, I wouldn't call it a fix up thread more of a pointless rambling thread.

Do a search for 'bucket update'

[Buddha#81]

Whats happening, the whole worlds holding its breath with excitment:shit:

[far queue]

Whats happening, the whole worlds holding its breath with excitment:shit:Yup, I've been wondering too :corn:

[kro]

Just waiting on the bike bits coming out of New Plymouth, but I'm off to ChCh Thursday and Friday, but I think the bike should arrive while I'm away, and the first major update will be Saturday 25th guys. Sorry about the drought, I have been waiting for the goodies to show up, and getting frustrated too.

[cheese]

What is happening with your bike? I'll be finished mine before yours!!! LOL it's a race!!

[kro]

The hideous bitch monster, otherwise known as my former sister in law, is attempting to split my family down the middle. Once I have dealt with all the drama this poisonous bitch is spewing out of her mouth, I will resume this project. Sorry to bunk out on you guys, but this is family, and it's major, so I gotta deal.

[Ghost Lemur]

The hideous bitch monster, otherwise known as my former sister in law, is attempting to split my family down the middle. Once I have dealt with all the drama this poisonous bitch is spewing out of her mouth, I will resume this project. Sorry to bunk out on you guys, but this is family, and it's major, so I gotta deal.

Fuck that Kro. The project is irrelevant, family comes first.

And once it's all sorted then you can celebrate by getting your baby running and go blow out the cobwebs.

If it helps (seldom does I find) you're not the only one. My ex filed papers to change the terms of her access, filled it with a bunch of bs, and will drag things out coz her and her bum husband can afford to with legal aid paying their expences. While Jay and I have to spend out hard earned (and sacrificed) dollars on lawyers fighting her. Rather than spending the money where it should be spent, on the boys.

Stay strong.

If it gets particularly bad we could always come to a I'll kill yours if you kill mine agreement. :innocent:

[kro]

Thanks Ghosty, this problem has been going on for nigh on 7 months, since my brother left her. She's extremely violent, and mentally ill, which makes for a wonderful combination. She is currently telling my side of the family that we are all a pack of bastards, and that my brother is the son of satan.

Hope your situation turns out for the best, mine's just reached it's critical mass point, and the whole family is stretched to its limit.

[NordieBoy]

Well with the goatee I could see where she could get that impression.
But I thought Satan would ride RED bikes?

[cheese]

what a whore. Why do people even get like this, what is the point, doesn't she know she is holding peoples lives up! do you have the coppers involved?

[kro]

Cops are heavily involved, but mental health services have pretty much washed their hands of her, as she has yet to actually stick a knife in someones gut, at which point, the knee-jerk mental health system we enjoy in NZ, will suddenly come charging in to "save the day", when in actual fact they could have prevented it in the first place.

At this point, unless I can get her out of Nelson, I will move to another town, as will my brother.

Don't get me wrong, the pain of separation must be a stinker, but after a few months, you would expect most sane people to cut their losses, and and least try to retain some form of amicable contact with the other party, and allow access to any children involved. This woman is stalking my brothers new partner, and has attempted to physically attack her as well, and this was 6 months after the initial split, we are now looking down the barrell of month number 8, and she is angrier, and more psychotic now, than ever before.

Hate is not a word I like to use, it is an ugly, destructive, unproductive word, but I hate what this woman is doing to my family, and to some degree, I hate her as well.

There, I vented, sometimes it helps to write things down, then read what you've written, to get some of it out in the open.

Fran, you never beep when you ride past me when I'm in the yard........ you have a horn you know !!!!!!!

[NordieBoy]

But it's a pathetic horn.

(The one on my new DR650 is better)

Ummm...
Which yard?

[Wellyman]

But it's a pathetic horn.

(The one on my new DR650 is better)

Ummm...
Which yard?
The one with broken suzukis all over the lawn....
WM

[kro]

I meant my work yard, not The_Dovers house Wellyman.

[NordieBoy]

And your work yard is...?

[cheese]

So you need some of my russian mafia friends to sort some things out so you can finish this bike?

[kro]

Kinda looking that way cheese. I am busy gathering more money as time goes on though, so that's good. I need to get a mountain bike though, a cheapie, but a goodie, if such a thing exists. So I'm kinda focused on that atm.

[kro]

As unfortunate as it is for me to say, Project DR looks to be dying before it's completion. Due to circumstances outside of my control, I no longer have the ability to fund the completion of it, and am therefore negotiating the sale of the completed rolling frame, and parts.

Sad day indeed. :bye:

[cheese]

That really sucks!!! what is needed to finish it? Wouldn't you'd get more for it complete?

[kro]

"Complete" is not something I have the money for unfortunately. I think I may have under-estimated the costs involved, and being a one income family, this new situation has effected me on a larger scale than I anticipated.

[Ghost Lemur]

As unfortunate as it is for me to say, Project DR looks to be dying before it's completion. Due to circumstances outside of my control, I no longer have the ability to fund the completion of it, and am therefore negotiating the sale of the completed rolling frame, and parts.

Sad day indeed. :bye:

Nooooooooooooooooooooooooooooooooooooo :shit:

Worst case senario, put a cover over it and revisit it in a year or so when conditions are better.

What bits are you missing? With all the engines that have gone through your hands you must have salvaged most bits needed.

[far queue]

As unfortunate as it is for me to say, Project DR looks to be dying before it's completion. Due to circumstances outside of my control, I no longer have the ability to fund the completion of it, and am therefore negotiating the sale of the completed rolling frame, and parts.Nah, you can't do that, not after all the work you've put in, and the anticipation you've had of getting this finished. Easy for me to say, I know, when I'm not in your situation.


Worst case senario, put a cover over it and revisit it in a year or so when conditions are better.What he said. Push it off to one side, until you can find the time and money to finish it, even if it takes a couple of years. This thread will still be here, so you can come back and have a read from time to time to remind yourself of the work you've put in, and the goals you've had.

Good luck with whatever you decide.

[kro]

What bits are you missing? With all the engines that have gone through your hands you must have salvaged most bits needed.


A working DR 250 top end, second hand, is a rare find, one I am yet to make.

Realistically, if I wanted to do it right, we're talking about 750 to finish it. I may have enough spares among the wrecks I have to do it, but then I'll be in the same place in 6 months time when it goes pop again. It's not all doom and gloom, I have proven I can do something like this, so even if I sell it, I can just do it to another bike once I have some money again.

[barty5]

dude i reakon that at $750 you got enough support here if everyone put in a few bucks $5 $10 youd get it done id be supprised if most people wouldnt help out a bit to see it finished ( and yes i know your response will proberly be i dont want to be a charity case ) but come on to come so far and not see it finished is a crime garanteed the person you sell to would see it for what it is and it'll be back were it started but up an account number youll get there .

[Wellyman]

Kro, I think I may have somebody that could help you....
he is selling his bike a DR of somekind I think, in CHCH.
I shall talk to him and see whats going down, because i think it broke something and aint running....
but shall give him a call and get back to you.
WM

[kro]

dude i reakon that at $750 you got enough support here if everyone put in a few bucks $5 $10 youd get it done id be supprised if most people wouldnt help out a bit to see it finished ( and yes i know your response will proberly be i dont want to be a charity case ) but come on to come so far and not see it finished is a crime garanteed the person you sell to would see it for what it is and it'll be back were it started but up an account number youll get there .

Mate, I'm humbled that people would even consider this, but yes you are right, I couldn't accept it anyway. Being the small one income family that we are, we do take some of Helens money back off her by way of family assistance payments, so any additional funds that show in our bank account, will reduce what we get, quite considerably, so thats really out of the question.

To be honest, I would feel more than awkward taking other peoples hard earned cash to fund my past time, I know I wouldn't feel right about it. I wouldn't see it as charity, but I still wouldn't be all that comfortable about it all the same.

I'll try and hold off for another week, and see how it goes.

[kro]

Kro, I think I may have somebody that could help you....
he is selling his bike a DR of somekind I think, in CHCH.
I shall talk to him and see whats going down, because i think it broke something and aint running....
but shall give him a call and get back to you.
WM


Thanks Welly, just remember, it has to be 1982-1985, I can't use anything outside those years that I know of, other than GN 250 gear (any year). If it is the right year, and he doesn't want the earth for it, I can get it to Nelson free of charge (thank goodness).

[Ghost Lemur]

Good to hear you're reconsidering kro.

There's a few wreckers down here that I've got to touch base with in the search of CRM bits (and knowledge). Will keep my eyes peeled for a DR top end while I'm at it.