welding on oem cycle parts

[cmoreride]

I own both of those bikes. Sure like the the motor of the KLE, and like the dirt potential of the KLR so someone with skill and motivation combined them. Ya I know custom, pricey, not feasible for the average owner. But I post not to start a debate but merely informore those who might find it interesting. Interesting 

[mechanizeinc]

Well, I looked around town for a scrap yard, casting house, fab shop or quality/inspection source that has an x-ray florescence spectrometer (hand held or otherwise) to inspect my parts and tell me exactly what material I have and therefore what requirements need to be met for welding. Namely, the type of rod used. This effort lasted a few weeks to no avail and finally I found a welder close to the house that welds a variety of cast aluminum regularly and has beautiful tig skills. I then hacked out a variety of nubbins from an old, ugly and bent (lower clamp) KLR650 clamp set and had him modify my KX450F clamps. It's done, pretty and on the bike. I started assembly last Friday evening and I'm now a few hours away from a running bike... The gauge and ignition bosses on the upper don't concern me but the steering stops could see some abuse. Oh well, short of catastrophic failure, its nothing $500 or $600 worth of custom machined clamps can't fix. Mechanician

--- In DSN_KLR650@yahoogroups.com, Jeff Saline wrote: > > On Fri, 27 Aug 2010 14:07:16 -0000 "mechanizeinc" > writes: > > First, imagine you're broke. > > Now imagine you need a vehicle and you decided to replace your > > wrecked out KLR by building one from the ground up. > > You've begged, borrowed, bargained and bought enough parts to build > > a Frankenbike. "Que the theme for Sanford & Son." > > > > In an effort to eliminate one of the biggest shortfalls of the KLR > > as designed, the suspension, you've come up with an upside down fork > > set... the complete front end offa KX450F for a dang good price as > > opposed to buying the stock stuff and required improvements. (FYI, > > you still have to buy improvements for the KX450F front end if > > grafting to a KLR.) Crap > > > > Emig makes a conversion stem. They also make upper and lower clamps. > > Their version of the triples as opposed to the KX, include steering > > stops on the bottom and bosses for the original KLR gauge cluster > > and ignition on the top. I don't know how much they charge for the > > set yet, gonna call Gary today. > > > > So the question is... how much risk is it worth to save some cash by > > cutting off the front sliver of the gauge and ignition bosses in two > > sections and welding them onto the front side (farthest away from > > stem of camps)of the KX upper and weld two steering stops to the > > bottom clamp? > > > > My immediate plan it to run without gauges and use an ignition from > > a 70's Honda CB750 that has round tube mounts build in and clamp it > > onto the bars or frame (realizing and accepting the loss of steering > > lock.) Gotta have the steering stops, though. > > > > Thanks for your consideration, > > Mech > <><><><><><> > <><><><><><> > > Mech, > > If I'm broke the last thing I'll need is a motorcycle. They aren't cost > effective for transportation. : ) > > But, if I decided to put one together and install upside down forks... I > don't think the ignition and gauge cluster mounting would be a big deal. > They only are needed for a minor amount of weight and aren't structural > to the steering/suspension. If the welder knows what he's doing I think > it could work well. > > As for the steering stops... That could be kind of iffy but still > probably very doable with the right welder. > > One issue I see needing to be addressed is the material of the triple > trees and also of the mounting parts and steering stops. If the > materials aren't compatible the welding won't go very well. A detailed > discussion of your expectations and the welders experience/skills and > abilities will helpful in having a satisfactory outcome for the project. > > May I suggest the following for the welding part of the project. Good, > Fast, Cheap. Pick two. > > Good luck with your bike project. > > Best, > > Jeff Saline > ABC # 4412 South Dakota Airmarshal > Airheads Beemer Club www.airheads.org > The Beautiful Black Hills of South Dakota > 75 R90/6, 03 KLR650, 79 R100RT > > . > > ____________________________________________________________ > Get Free Email with Video Mail & Video Chat! > http://www.juno.com/freeemail?refcd=JUTAGOUT1FREM0210 >