Botty's 4l0 Hybrid

[botty]

A recent Ebay purchase saw the basis for my hybrid.

It's basically all there apart from exhausts, it has it's original 350 top end but has a 4l1 bottom.

I'm going to keep it subtle, lots of black powder coat and anodizing.

Standard to look at apart from ZXR 250 running gear.

As it arrived.



ZXR 250 front end went straight in with only a new set of taper bearings and a 5mm spacer ontop of the top bearing. The lock stops are in the correct place too.



The ZXR swingarm looked a tad too long.

So I've opened up the standard swinger using a crude jig to keep the right side rigid and allow me to open the left side with the use of a blowtorch and a bottle jack.



Assuming the centre of the swingarm pivot is the centre line of the bike, the wheel is central +-2mm

[stfocus]

Looking good keep it coming am thinking of doing one but the price of the bike r getting expensive as everyone wants a winter project 

[mikee]

Eee bee a goddam boike buildin machine

Get on wi it me hearty

Aaaharggg


Mike

[arrow]

Nice project Tony.

[dusty350]

Looks a great project Tony. Could you not use a Kr1s/ Kr1 swingarm ? I'm not a fan of bending old thin tubing like an Lc swingarm. I'm no engineer, but the Lc arm was never regarded as strong when new, so wouldn't be happy doing this.

Dusty

[oldelsieboy]

Nov 19, 2014 9:18:59 GMT 1 dusty350 said:

Looks a great project Tony. Could you not use a Kr1s/ Kr1 swingarm ? I'm not a fan of bending old thin tubing like an Lc swingarm. I'm no engineer, but the Lc arm was never regarded as strong when new, so wouldn't be happy doing this.

Dusty

I'm with Dusty on this, chunky USD forks & spindly tubular swingarm just don't go.

OEB

[dusty350]

Hi,
My concern is with the integrity of the tubing/welds on the swingarm when it's put under stress. When I've chopped various bits of frames in the past, I have nearly always found corrosion, some quite significant, on the inside of the tubing. I know guys spread frames, but they are welded up afterwards. Just wondered if Tony was going to brace the arm at all to add some strength back.

Dusty

[dusty350]

I had a Kr1 swingarm in the Yamasaki, which is a bit longer than a standard YPVS arm ;



The issue would be adding a top loop for the shock absorber if you wanted to keep the standard suspension set up. I think the Zxr400 has a top brace as standard that you could possibly utilize.

Dusty

[botty]

I see where you are all coming from.

Thanks for the heads up.

I was going to fit the zxr swinger, but thought it was a bit too long. It's about 4 inches longer than standard.
If it was a bit shorter it would be on there.
I will have a look to see if I can shorten it.
Maybe cut off the privet point and have it moved back or lengthen the chain adjuster slots to move the wheel further in.

[dusty350]

Hi
I cant remember how long the Kr1 swingarm was, but I think I used a chain with 110 links in it. I know Rgv swingarms are longer than standard, but again, I don't know by how much. I was just worried that an old bendy swingarm such as an Lc's wouldn't take kindly to extra stress. Maybe if you braced it in the right areas it would be ok. Someone like Nigel at Nk would be the fella to ask, he has always been forthcoming with advice when I've spoken to him in the past. It will be a great project whatever you do though Tony, you do build lovely specials

Dusty

[iwantalc]

definatley got your work cut out good luck

[botty]

I'm thinking maybe under brace it too.

I had a sense of direction which appears to be changing.

I have another arm that I could probably bend some new side rails in bigger material and use.

As for NK. No thanks. I spent lots of money there in the past, only to be given bullshit.

And quite frankly the work he has done, has had to be rectified.

I don't know which way to go with the swinger now.

I will continue mocking it up as it is, and look at modifying the zxr one to work like a standard one.

[markhoopy]

Lots of hybrids have swinging arms that are clearly too long for the bike they're grafted in to and just look wrong .. if the extra 4" can be cut out of the 'arm then that would be a good way to go maybe?
I agree with previous comments on your LC modifications needing some kind of bracing if you stick with using it, but if it works out it will certainly be something a bit different

[mikee]

Tony , have a look for a yz400/465/490 swinger , old aircooled ones
They fit easily in a 4 lo frame and look good too , only need a bit of dicking around to fit them , take a wide wheel too

Might not be that easy to get a hold of these days tho



Looks like this
Mike

[4l04ever]

I fitted a 17" TZR125 rear wheel in my standard swing arm to keep the original look and swing arm length. Looks good and handles well.

[botty]

Nov 19, 2014 23:30:24 GMT 1 mikee said:

Tony , have a look for a yz400/465/490 swinger , old aircooled ones
They fit easily in a 4 lo frame and look good too , only need a bit of dicking around to fit them , take a wide wheel too

Might not be that easy to get a hold of these days tho



Looks like this
Mike

Had a look Mike. Some on Ebay. From the states though.

Going to have a crack at Bracing the standard one. Easiest option. Might even just leave it.

[dusty350]

Hi,
I looked at those arms in the past after finding info the the US forums. The only ones available were on US Ebay
I had a rare box section Hejira arm on my 400, and you can see some bracing in this pic;



You'll also need to consider a way of fixing the torque arm, this is the Hejira mount;



Another swingarm that is very close to fitting an Rd frame is a Tzr250 2ma, albeit a bit longer again;





Hope that helps

Dusty

[botty]

Thanks Dusty. I'm going to have a go at redoing a Standard arm, simply because I have a spare one.

I will be copying the Hejira torque arm mounting.

Thanks Tony

[botty]

Made a crude jig to try and widen and "beef up" a standard swingarm. JUst thought I would give it a go as I had a spare.

Marked out the standard arm dimensions on the board, then overlaid the zxr swingarm dimensions.

The rear axle mounts are set up at the same width as the standard arm plus 4mm each side to allow for the chain adjusters.Made it 50mm longer than standard.

I'm going to cut off the side arms to leave just the pivot and bend some bigger pipe and get that TIG welded in place, then reset the shock mount points, also beef up those rails too. Maybe also underbrace it.

If it works happy days. If not it's only cost me time and no outlay.

You never know Metmachex started off by modifying arms, now look at them

[botty]

Been working on the swingarm on/off. This is it so far.

Bent some new side rails. Inserted the adjusters into the new steel and had it TIG welded .









I was going to utilise the original shock set up. It's not going to work, So going to fabricate another.



I have 2 tanks to choose from. Both have issues, so sent them off to be acid dipped. This process removes everything apart from "good" metal. Filler, sealer/liner and rust.





Tank 1. The black one.This felt really heavy compared to the other one. Liner and filler. I knew the right hand side was filled, not to what extent. I ran a magnet over the tank and it fell off on the right.











Tank 2









They both look bad. Both repairable though. Tank 1 is going off to a man who can fix it. Also the rest of the panels are going too. Will get them back painted in their new colours.

[stfocus]

Who doing the tank repair and how much as I've got one to get done and a good build keep the photos comeing 

[botty]

It's a friend of a friend who is doing it. I will see if he will take anything else on.

However he is abroad at the moment.

[dusty350]

Good work there Botty, the swingarm is gonna look good.
Looking at the dents in that tank - a tank slapper with clip ons fitted do ya reckon !

Dusty

[botty]

Dec 21, 2014 17:58:24 GMT 1 dusty350 said:

Good work there Botty, the swingarm is gonna look good.
Looking at the dents in that tank - a tank slapper with clip ons fitted do ya reckon !

Dusty

Some tank slapper

With you on that Dusty. Looks like it's been hit with clip ons, switch etc. Decked it maybe??

[botty]

Dec 22, 2014 10:44:05 GMT 1 headcoats said:

Keep us updated on how the tanks get fixed Botty

Will you put a liner in after the repairs ?

Will keep you updated Mart. If I get sent some progress pictures as work progresses.

You have the before, likelihood is the next time you/I see the tank it will be painted. If it gets a liner it won't be me putting it in. Last time I did one it peeled off over night.

[compo]

Interesting build, keep up the good work

[botty]

Dec 23, 2014 1:18:26 GMT 1 compo said:

Interesting build, keep up the good work

Thanks Compo.

A bit more done on the swinger.

Clamped the standard one next to it to get the shock mount in the correct place. The longer arm wil jack it up slightly.



Starting to take shape



Need to slot the top rails to sit on the adjuster plates in the right place

[botty]

Taking shape

[botty]

Nearly done



Template for gusset plate. Will make that later.



Off to get it finally welded on Wednesday hopefully

[botty]

Fingers crossed. Being welded together on Wednesday