1986 CR 250 RC project/rep/build up.. IT'S FINISHED!!!

I decided to do a disc conversion on it... So once id got the frame all blasted.. out came the grinder!










I wanted it get the conversion to look as close to the works bike as possible. It took a lot of work as I dont have a works rear master cylinder. I had to find away to move the stock one as far forward as possible. In the end I got it 14mm further forward than the stock 1987 position. I had to machine up a special res take off.







I think I got it pretty close!

Once it was all powder coated it looks spot on!









I fabbed up the alloy guard. I made it a little different to the factory one. It wraps round the master cylinder a little more. I also got some HRC hose for the res take off.

We make our own yokes so I got these anodised a little different to match the factory colouring.




It's moved on a little more than this, but I'll get some more photos up later!

Stevie

Ive gone with later model hubs ('96) I couldnt leave them std though! I got them on the lathe and skimmed all the casting marks off.



They look pretty good powdercoated!



All the engine cases were vapour blasted before they were powder coated. Everything is "new". The old cases were so bad I had to junk them. The barrel was well beyond repair and the clutch case was.. as usual with the earlier bikes, rotten. I got a nice 91 alloy clutch case.






I had to knock up a pair of billet coolent take offs.

I've gone through it and made everything it titanium. All the washers, top hats, engine and suspension bolts. Everything!



That's my version and the HRC one on RJ's bike in the back ground.



Engine bolts, all EXACTLY as per the original Honda ones, just in Ti.



Suspension bolts



Stem nuts. I've done the top nut "one piece", so the washer is part of the nut.



Close up of the handlebar top bridge and the Ti bolts.



Got the later hub fitted into the forks. I had to make special spacers and sleeves (titanium) to get it to work with the earlier spindle. The disc bolts and nuts are Ti aswell.

Yeh thats me. Well, Phil's my Dad, he has a nice comfy chair in the office!

Thanks! The CR 480's were real labours of love! I put way to many hours into those!

I've got a Pro-Circuit pipe for this one, but I've made my own silencer. I should have that finished next week once the bits come back from anodising.

I'll keep the pics coming as I get stuff done. Customers stuff always comes first, but I get to sneak 1o-20 mins here and there!

Stevie

I had all the stock '86 shock linkage parts vapour balsted, but they still looked crap.... I saw a picture of the linkage on Malherb's '85 RC 500 supermoto and thought... I can make that!!....







They came back from the anodisers today..... I though they looked pretty cool before they went.... but I admit, I let out a little girly giggle when I'd unwrapped these 2...

Thanks! I wouldn't say a replica... But definitely inspired by!

Thanks for the positive comments guys!! Things are crazy busy this week but i have been able to get a bit more done in my lunch breaks and evenings.

I got the head steady machined out of 4.5mm carbon sheet. I made an alloy set aswell... but I dont think I'll be using them!



Finished the silencer. This really made my head hurt!!! The original silencer on the '86 is a 1 piece extrusion that is quite frankly, a work of art! You'd never see something like that on a modern bike, it would cost way to much! My silencer had been mangled, and had had extra holes hammered through it. It was scrap. My original idea was to cut the silencer and use the original inlet and just slip inside the carbon tube. Simple... or so though.... The carbon tube I could buy is not the same shape as the original alloy silencer... aghhhh!!! It's the same hight but it's narrower... so I had to have a rethink... I completely machined the inlet flat, so there was non of the alloy tube left. I then machined up a new "stub" that matched the new Carbon tube. I set the original inlet into it and then welded round the edge. So, now I have the orignal alloy extrusion inlet, that fits nicely into my new carbon tube!! I had the inlet vapour blasted to clean it up.



Machining the hanger bracket was a right pain in the ass! As the silncer is off set it made programming it a bit "more involved"! I'll be bonding a captive nut on to the back of the hanger.



Close up of the hanger bracket, and the hanger itself. The orignal hangers were trashed, and they are no longer available! Machined a new pair up and had them anodised. The bolts are TI, as is the hanger/fender spacer, mine was missing and it's not available from Honda! The rubbers are new.



Close up of the Inlet, Ti bolt and top hat, new rubber. You can see the extra weld around the edge where I put the new stub on.

Artsie IG shot of the front fender washers, collars and bolts.



The forks are fully rebuilt, the lowers were cleaned up on the lathe, then vapour blasted, the stancions have been re-hard chroming. NOS fork gaitors, the orignal gaitor clips were actually pretty good condition but they looked really scabby, re-zinc plated they look good as new! New OEM bushes, and seal.



New hose clamp, with Ti bolts.




Oh.... I got the linkage fitted!!