« Reply #2 on: August 01, 2011, 12:56:39 pm »
Tacked the rear subframe in place last night and machine some sleeves to mount the rear guard. Have to finish the rear tank mount next and then finish welding out the frame. Getting close to a rolling chassis now. Looks OK I think, and measures up pretty much the same as the KLX with regards to wheelbase, rake, seat height etc. I would think that the DT motor would be a bit lighter than the KLX motor, so it should work OK. Still got all the fiddly bits to do – brake pedal, torque arm, chain rollers and wear pads.![](http://img.villagephotos.com/p/2005-8/1062154/pete%204.JPG)
Got the front engine mounts fabricated and installed. Shortened the swingarm by about 40mm and welded the new tube in. Made swingarm bushes out of nyloil, which is self lubricating nylon and was only $25 for a 40x300 bar. Really easy to machine and should last longer than the needle rollers that were in there. Welded a lug on the bottom triple tree (spare one from you) so I can bolt the YZ guards up to it. I then powder coated both the top and bottom trees, ready for installation. The next thing to do is mount up the swingarm and shocks so that I can weld the rear frame on and make the rear tank mount. All going pretty well so far.![](http://img.villagephotos.com/p/2005-8/1062154/pete%203.JPG)
Repaired the crank on the weekend. It was rusted really badly and after I blasted it I noticed the timing side seal surface was heavily pitted. I could buy a good second hand crank off ebay but I’m trying to stick to the budget so I machined down the seal surface 1.5mm and then made a sleeve out of an old gearshaft and shrunk it on, then machined it back to size. I also took a clean-up cut off the outside of the wheels – only a couple of thou so it shouldn’t affect anything. Put the wheels back together and trued them ready for motor assembly.![](http://img.villagephotos.com/p/2005-8/1062154/pete%2011.JPG)
![](http://img.villagephotos.com/p/2005-8/1062154/pete%2010.JPG)
« Last Edit: August 01, 2011, 01:20:57 pm by firko »
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'68 Yamaha DT1 enduro, '69 Yamaha 'DT1 from Hell' '69 DT1'Dunger from Hell, '69 Cheney Yamaha 360, 70 Maico 350 (2 off), '68 Hindall Ducati 250, Hindall RT2MX, Hindall YZ250a , Cycle Factory RT2MX flat tracker, Yamaha 1T250J, Maico 250 trials, '71, Boyd and Stellings TM400, Shell OW72,750 Yamaha