winter rebuild of jeff that changed everything

reckless

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Aug 12, 2013
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this is jeff before things changed for ever
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now im a big two stroke fan but have ended up with something a little different, many of you will ask why even keep a blaster with what i have ended up with but i like the size of these quads,

i took jeff out for his last ride begore i planned on having the piston replaced when i hit a big rock, the rock caused the chain to come off resulting in it wrapping round the gear changer and causing a bit of damage
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id already bought yzf450 panels to fit as my winter project so wasnt overly upset about the damage as repairing the casings wouldnt be to much of a hardship, but then a YZF250 came up cheap and i thought id try it for this summer to see what its like.

i will be updating this over the next few weeks as the fitting of panels and a YZF250 hasnt been covered in depth before,
 
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does anyone know why my pictures will not load when i link from photo bucket

you're prolly using the wrong IMG code ?
use the ones for forum/message boards
or....just use this forums upload
 
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so after a false start here is the damage caused by chain
b511c32d-cdbe-4713-b644-1913c9cc9d75_zpsbfc4459f.jpg


it was a pretty sad way to end a summer of good riding and given the treatment and hours on this engine it was the last thing i expected to go wrong. it was how ever only a matter of time had this not gone that a total failure would occur as the piston was cracked all over (not bad for little over 100 hrs hard riding).

for any one reading this who thinks i got rid of the blaster engine because it wasnt enough or was to slow,, dont i love a challenge and to mess around with things normally on a shoe string budget and plus my mrs watches crap on tv so id rather be in garage lol.

so here is how the build started
c889d205-3837-4878-9e2b-22e9eff2b29e_zps92ba0163.jpg


i will try to cover every thing in the order i have done it. it may not be the best way but its a start if your considering this.

now i am aware the my welding and fabrication skills arent the best you will ever see but im learning.

list of parts that are being used in this build.

2003 YZF Parts

front brake caliper
rear brake master cylinder
engine / carb
radiators
handle bar set up
exhaust system
air box boot to carb
2010 oil tank and left hand oil line (2003 has tank built in to frame)

2007 YFZ450 full plastics set

so first i started with the plastic as i had no idea on how to make them fit and wouldnt be able to mount exhaust or radiators as i fitted engine with nothing to go to. will get some better pictures of mounts and post up tomorrow as the ones i have on phone arent the best
 
How are you putting on a "handle bar setup" from a yz250f? (not a yzf250) do you mean just the bars? This thread has us all confused i think. Poor jeff is loosing his manly hood with that new heart.
 
Apologies for confusion ive never even thought about posting blogs or anything until i thought of sharing this so bear with me,

yes unfortunatley a gender change just for something different will be back with another smoker soon but for now the CR 125 is my sole smoker for fun,

handle bar set up---- throttle clutch decompression lever kill switch and front brake front brake.
 
cb3ba11c-4dfa-411b-aa9e-000c29a08529_zps3e1a4cfe.jpg


the pic above shows where on the front i have mounted the brackets for the front panel
8e71f3fe-8148-43d8-8041-95ca06d6cdcb_zpsaa38e78b.jpg


here is a side view of the front mounts
b9d814f5-e8ae-49a4-9438-013266e2ead5_zps30e9eda4.jpg


showing front panel on mounts
5d554db6-6812-4981-a595-a7c100a36466_zps30eba5b6.jpg


a side view of a unfinished modification to rear plastics
eb648a24-50e4-4218-be1d-554cabba6797_zpsda177a81.jpg


air box cut out as to wide for frame
03910634-1614-47d0-a1c0-10e886dae822_zps0cc7b5d0.jpg


a mount to be welded on to secure part of rear panel shown below )not yet done)
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796685a7-4516-4f56-ab64-0f61762662eb_zps9438a76e.jpg


rear mount bolted on to existing mount to hold rear panel (bit heavy duty but its just a mock up)
e7c2a9aa-6a65-4e27-b70f-9f0e2aab7f4f_zpsa9d63da4.jpg
 
the front panels are wider and obviously not ment to be so with a little chop here and there
af6fa98b-b895-447f-aaae-4cf2f6463e10_zps7e932d4a.jpg



now for the panels mounted
907183c8-07ab-4c1b-9eef-18e3e59aa617_zps6ec0190e.jpg


now i know that the gap at the top by handle bars is a sore subject for mounting these panels as i am keeping the blaster tank and seat for this build but that didnt stop me trying,

first things first make a mould i used air drying clay
f1bda867-9d1b-4295-b74a-a55f4c308726_zps0297c50a.jpg


it did take some time to get right but there is no easy way around it

i then found a good product called plastimorph which is pellets you heat in water to form plastic
49066608-2d62-4e01-abce-96f491849b9f_zps2870cf49.jpg


you can add colour to the soft plastic too and roll it out with a rolling pin re heating as required

here is the what i ended up with not perfect but for a first time using this its not bad

ba0a2ba0-d90b-4b18-a4c0-94c9162e048c_zps67584aa1.jpg
121f5c67-68f7-4ae0-ba5a-77e125cf10fb_zps1389fce9.jpg


i will be making a fibre glass version to but i thought id share this as its food for thought

1ec647c6-c16f-4d92-b02d-9ae3b05eb73c_zpsc8786bbf.jpg


thats all i got time for but remember these panels have only been roughly mounted to give an idea as to where im putting the rest of the bits so no negative comments about the finish, thats the last thing on my mind yet

be back soon to get to the real work hope this helps everyone out
 
-Will there be a name change? Jennifer, maybe?

-And what's up with those a-arms in that last pic? Got any close ups of them?

-MacDizzy had a write up of a DT200/Blaster hybrid that showed how he mounted the radiator. Might wanna check into that.

Also, what's going to happen with the blaster engine, carb, and pipe?
 
First off I admire you're creativity. Not having the plastic you needed you say heck "I will just make it myself". Two thumbs up for that.. What a arms are those? Alba maybe? Also what rear shock?
 
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-Will there be a name change? Jennifer, maybe?

-And what's up with those a-arms in that last pic? Got any close ups of them?

-MacDizzy had a write up of a DT200/Blaster hybrid that showed how he mounted the radiator. Might wanna check into that.

Also, what's going to happen with the blaster engine, carb, and pipe?


ha ha yea jennifer could be the new name,

the quad is on a on dolly so the arms are hanging down making them look steep. cheers for radiator advice they are mounted already im 90% done just waiting on swing arm to come back and a few other bits before i clean up all welds and send to powder coater.

the engine casing has been repaired but are just in a box with all the parts, i may rebuild for a go kart for kids or sell it off if some one wanted ont the pipe i sold and only got standard carb (anyone in uk need a basket motor or carb let me know would let it go cheep to help a fellow rider out
 
First off I admire you're creativity. Not having the plastic you needed you say heck "I will just make it myself". Two thumbs up for that.. What a arms are those? Alba maybe? Also what rear shock?

cheers, this is my first project of this type but i wanted something different with panels (the engine change was just down to bad luck) but seen bad press about the gap and thought theres a challenge for winter, i cant recomend the product enough for all of repair needs http://www.instamorph.com/

i havent got a clue as to what arms are but i will take some better pictures when i strip it for paint in a week or so as for rear shocks it has works pro series all round although they will be making way for some custom shocks after build is done
 
will have oil tank fitted monday and will post pics of engine mounts and alterations as i strip it back out