Project DR second edition

[kro]

The bike arrived from Waimauku yesterday, pretty much exactly as I expected it would be.... a bit of a roughy. I couldn't help myself, and turned the fuel on, and gave it one kick...no choke, and it fired instantly......MAGIC JOHNSON !!!!!.
It's actually hard to hear whether the top end is quiet, as the pipes drop directly off the head, and go down about 8 inches, and that's it........ she's LOUD !!!!. I think it may have had a GN zorst on it judging by the direction the pipes head..... straight down.

This will be one hell of a frankenstein bike when it's done, I will be transplanting and grafting all sorts of bits onto it from my extensive DR library. I will not be giving this bike the same level of attention that my first DR, it will be cleaned up just enough to sell, but will look so good, I should get good coin for it.

The bike is rustier than a KE71 Corolla that's been driven its whole life on Muriwai beach, so the first major course of action will be a frame transplant, as I suspect that if ridden off anything higher than a 2 foot drop off, she'd fold faster than superman on laundry day. I have two spare DR frames, so I'm good to go there.

The progress on this second edition will be slower than the first, but hopefully will be of interest to a few of you. Now that I am riding my mountain bike a 100k or so a week, I have a bit less time to devote to other things, but I will eventually finish her.

Tomorrow is motorcycle porn day, as i strip her naked... pics of that to follow, meanwhile, here are some snaps of it "as is"

[kro]

The rest of the pics.

Check out the horrendous rust and pitting on the upper fork stanchions, it's unbelievable. Mind you, Waimauku is a short hop from Muriwai, so I can guess where she's been ridden.

[Steam]

THat's the ugliest DR I have ever seen! I will be watching the project with interest, as I'll be in the market for just that kind of thing in a bit.

[paturoa]

......MAGIC JOHNSON !!!!!.

......... a frankenstein bike when it's done

...........rustier than a KE71 Corolla that's been driven its whole life on Muriwai beach,

........she'd fold faster than superman on laundry day

....is motorcycle porn day, as i strip her naked...

lol - bling for those

[kro]

THat's the ugliest DR I have ever seen! I will be watching the project with interest, as I'll be in the market for just that kind of thing in a bit.

I've had 4 whole DR's, and several partials/engines thru my garage in the last 8 months, and this is the worst of them all. The thing is, I relish the opportunity to make the best of these old dungers, and make them look good again.

As I said, I have a bare frame thats not full of rust, already stripped bare, so I will paint that up first, then it's just a case of stripping bits off this new crapper, tidying them up, and grafting them onto the good frame, it will be easier than Project DR was originally. My only concern really, are the forks, but I may get away with them, I will see.

[kro]

I've updated my little picture collection a bit to include the second bike.

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

[kro]

Here is the frame I am going to put everything in/on. This frame is courtesy of a lovely chap named Neville, who resides in the Lud Valley here in Nelson. The original frame is pretty munted with rust.

[Motu]

Good luck! Like you I will be doing an XT revisited thread soon.Yesterday (sat) I drove down to Wanganui and picked up another motor and stuffed bike in bits as well....then back home.11 hours in the Pajero,don't tell me these things aren't useful.Now I have a shit load of unrelated XT spares.Reminds me of my younger days when I had a whole bedroom in the house full of BSA single parts....because there was no room in the double garage for them...or a car.

[kro]

I will be looking forward to seeing that Motu. Let me know when you start cranking up the work on it.

You are dedicated to drive 11hrs, my bike came from Auckland, but I got a mate to drop it at our Albany branch, and it came on a truck :P

Looking forward to seeing the Yammy.

[Motu]

I have a time limit,if I don't do something in the next few weeks the bike goes into storage and I won't be able to work on it until maybe this time next year.That's why I decided to go with another complete engine,the bike still goes into storage,but hopefully as a runner and not boxes of parts to mislay.I will still be able to get the bike out for rides.

[NordieBoy]

I may have mentioned this before but...

I've got a client who was working on a Triumph gearbox and got a couple of months work in Aus.
Rag gets thrown over g-box on bench.


6 years ago.

[kro]

I couldn't do that, I can't stand things unfinished.

[kro]

Whilst the the sun is sunning, I am getting all my painting done, it's primo painting weather. I painted the frame last night, and jammed it in the Skyline, to bake all day in the scorching heat. Cars are such cheap bake ovens, I love my Skyline very much. I chucked a couple of clear coats on it tonight, and have chucked it back in the bake oven.

I took the handlebars off, to get the top clamp off, and I think I can get a good portion of the surface rust off the stanchions.Pics of that later, but here is the painted frame, done in red, which in the light, and my stupid cheapo camera, looks pink.

[kro]

This aint much to see, just the bike with no top clamp. The stanchion closest to you I rubbed a bit of 400grit wet and dry over, and the rust virtually disappeared, so I may be able to buff these puppies up a bit. The fork seals leak like a sieve, but this is a budget project, so the next owner can do them.

[FA50 rider]

good luck m8

[kro]

If anyone has a crusty old set of fork boots they would be willing to part company with for low or no dollars, I would love to hear from you asap.

Thanks

[kro]

I'm charging ahead with this second bike, and will have some more pics later this evening, I have basically revamped the whole front end already.

So easy the second time around......

[kro]

Taken today, after a particularly productive session. I am going a bit kamikaze with this one, and just charging into it, not taking quite the same care and attention to details.

The ugly grey blob pic is the fuel tank, which I can only surmise is actually a Honda tank, as the last colour to strip off it before it went back to bare metal was red. The paint was thicker than a blond supermodel, and damn near as abundant. I had to get the wire wheel out for that baby. The tank is only primered in this shot, I should have at least one coat of it's final colour on it today.

[kro]

Next installment

Oh no they cried, he used that damn anodising effect paint on the brake arms again !!!!!. I didn't use it on the fork yokes though, that took me fuggin ages the first time round. No DR picture is complete without a shot of my trusty Skyline in the background

[kro]

Next installment

In case you're wondering, I am going to finish the original DR project, I am just doing this second one for some extra coin, and the engine from it to power the original DR, and I will plonk the slightly noisier donk into this second project bike. I need help with the engine stuff, it's not something I know how to do.

[kro]

Did a bit more today, wire wheeled the sidestand, brake stay arm, and painted/clear coated them. I have buffed up the rear sprocket hub a bit, and also the chain guide. I have the swingarm off now, and will be hitting that tomorrow with a veangence.

I am going to do the shock shortly thereafter, and that will allow me to slap the read end into the old girl too. I already have the shock pivot, and "A-arm" painted and clear coated.

I have "painted" the tank, and it's a bit of a rough job, but I will laquer it tomorrow, and that should shiny it up a bit.

Pics tomorrow

[Wellyman]

Good luck kro!
looks like another good project.

[kro]

This is the fast resto bike. I am not being nearly as fussy this time round, but the bike will look sharp for a cheapie when it's all done.

[kro]

Finally got some time between school swimming sports, and mountain bike riding to get some work done on the 2nd edition.

A-Arm
Awing arm
shock
pivot-arm

All in place, and looking pretty good, considering I did all this today, and if it were the original DR, it would have been a few days worth or more.

[kro]

Got the front and rear wheels masked up, and sprayed. Sorted out the rear end, and attached the chain guide, and got the back wheel on, and also the mud spray "curtains" that attach to the a-arm.

Tomorrow, I should have the front back together tomorrow, and maybe slap the bars and sidestand on it.

[NordieBoy]

Oooohhh
Shiny...

[kro]

Not nearly as shiny as that beast behind it.....

[kro]

Got everything except the bars put on. The tank is definitely not a DR tank btw, it's gonna be a pisser to make it fit to my liking.

Looks good with wheels, a rebuild only starts looking like one, when the wheels go on. Tomorrow, I may have a break, but if I do some work, I will do the rear brake connections, and get the bars on, and secured. I found a sidecover for the airbox (phew), and realised in the process, that I don't actually have a damn exhaust for this bike... grrrr... I will find something to do the trick. The bugger of it, is that I damn well had one 3 weeks ago, and sold it to help fund the purchase of the bike...lol.

I will figure out all the details later, I will take a trip to Baz Bikes, and see what he can do in the way of a header pipe, and I'll get a cheapo muffler made up for it locally, unless some generous KB'er has a muffler lying around somewhere............. :cheeky:

[Dirty DR]

hey Kro, you dont have any spares to sell do you? I urgently need a kick start lever, clutch and exhorst. i picked up an 82 dr250 but with no clutch and no kick i cant test it. thanks

[kro]

I could possibly do a clutch matey, but I don't have any kick starters, or exhausts sorry. Have you got the clutch basket at all?. I have probably 3 whole clutches worth of plates, but perhaps only 1 clutch basket that would be worth using.

I have no idea what the parts would be worth to be honest. I have sold just about everything else on a DR, except the clutch.

[FA50 rider]

dirty DR heres some stuff i just found go check it out you might find what your lookin 4 http://www.trademe.co.nz/Trade-Me-Motors/Motorbikes/Motorbikes/Dirt-bikes/auction-90843326.htm

[kro]

Murchison, I could drive to Murch for another DR !!

oh no they all cried !!!!

[Dirty DR]

I could possibly do a clutch matey, but I don't have any kick starters, or exhausts sorry. Have you got the clutch basket at all?. I have probably 3 whole clutches worth of plates, but perhaps only 1 clutch basket that would be worth using.

I have no idea what the parts would be worth to be honest. I have sold just about everything else on a DR, except the clutch.


i have a complete clutch its just the plates are smoked. im guessing the previous guy was push starting it coz he told me the engine was seized but its not. how much $$ you want?

[Dirty DR]

dirty DR heres some stuff i just found go check it out you might find what your lookin 4 http://www.trademe.co.nz/Trade-Me-Motors/Motorbikes/Motorbikes/Dirt-bikes/auction-90843326.htm

cheers for the link, man iv been checking trade me every day but missed that one some how. Ive emailed him. thanks

[kro]

i have a complete clutch its just the plates are smoked. im guessing the previous guy was push starting it coz he told me the engine was seized but its not. how much $$ you want?

I'll check tonight if I don't end up working, and let you know either tonight, or tomorrow morning what I can or can't do. I have no experience in clutch plates, and don't know how to identify bad plates, so I will be winging it a bit.

[Dirty DR]

If you could hook me up with some clutch plates kro that would be PRIMO. The lady on trade-me with the DR said yes to me then sold the engine with the clutch and kick lever to someone else. I was gutted. thanks man.
p.s sorry to hi-jack your thread.

[kro]

No sweat man. I am hitting the garage again tomorrow, after a week or more with no time to work on the bikes at all, so I will find the plates etc, and contact you thru the forums.

[kro]

Sorry about the lack of response. My last 5 or 6 days, have been full, and I haven't done a damn thing on either of my bikes. I have the bits you need, please pm me a street address/ name etc, and I will put these on the courier tomorrow for you.