JUST ANOTHER 2016 KTM 250SXF CHASSIS KX500 ENGINE CONVERSION GONE MAD!

Sandblaster
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2/10/2018 8:00am
sende wrote:
This build keeps me on my toes. I always check this thread first when I come here. Quality job.
Wow... That's cool.... Thank you!
I'll be posting more on this build soon... I've just been buried in 1,000,000 other projects....
I can't show any pics but my custom drum valves are almost done.
I will by dyno testing them in a completely stock KX500 to know where and how much if any these valves help.
I'm pretty excited about this mod.
I've been sitting on it for about a year and decided this would be the build that I install them...
More on that later Cool
Sandblaster
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2/12/2018 4:48pm


Thank you Works Connection!
4130 Product Drive
Cameron Park, CA 95682
Phone 530 642 9488
Fax 530 672 9386
E-Mail: info@worksconnection.com

https://www.worksconnection.com/

I have used Works Connection products for many years and have been more then satisfied.
I'm certain these will be perfect...
Thanks again Works Connection!!





bf884
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Belle Chasse, LA, USA
2/12/2018 7:30pm
Question about your vapor blaster. Is it basically a pressure washer with a media hose? I’m trying to do a budget blaster. I was thinking the Eastwood media adapter with a short trigger handle. Any info would be great
Sandblaster
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2/12/2018 8:52pm
Mine is all enclosed in a Stainless steel cabinet



It functions more like a media blasting machine except that is uses a 85% water / 15% glass media mix which is driven by air.

I have seen the pressure washer style but have never used one.
Be careful around paint, it won't strip as fast as a waterless system but it will still remove paint if left blasting a spot long enough.

Feel free to ask any more questions you may have.

The Shop

Sandblaster
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2/13/2018 2:35pm Edited Date/Time 2/13/2018 2:36pm
Renthal did me a huge favor in providing a chain and sprocket set... Nice!!!
I can't wait until I get these parts on so I can take this thing for a rip... 8-)

https://www.renthal.com/shop/
Renthal (US Office)
Telephone (Toll Free): (877) 736-8425
Telephone (Local): (469) 707 5200

Renthal (UK Office & Factory)
Renthal Ltd.
Bredbury Park Way
Bredbury,
Stockport,
Cheshire, SK6 2SN

Telephone: +44(0)161 406 6399













onefiveight
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2/13/2018 5:17pm
Mine is all enclosed in a Stainless steel cabinet [img]https://p.vitalmx.com/photos/forums/2018/02/12/243802/s1200_VAPOR_BLASTER_2.jpg[/img] It functions more like a media blasting machine except that is uses a 85% water /...
Mine is all enclosed in a Stainless steel cabinet



It functions more like a media blasting machine except that is uses a 85% water / 15% glass media mix which is driven by air.

I have seen the pressure washer style but have never used one.
Be careful around paint, it won't strip as fast as a waterless system but it will still remove paint if left blasting a spot long enough.

Feel free to ask any more questions you may have.
Thanks for sharing, I’m obsessed. What compressor are you running?
Sandblaster
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2/14/2018 8:14am
It's a Ingersoll Rand 7.5 HP 220 single phase (So I can plug it in to a Dryer plug Lol)
As long as you don't turn the pressure up too high it works fine.
Anything much over 70 lb and you will run for about 8 minutes and then let charge for 2 minutes.
With vapor blasting, less pressure and finer glass media leaves a higher luster..



onefiveight
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2/14/2018 12:06pm
Amazing. I will have one, I must lol
Sandblaster
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2/14/2018 12:33pm
Amazing. I will have one, I must lol
Lol..
Yeah... It's pretty nice. If you decide to pull the trigger on one, hit me up and I can save you a LOT of time trying to get started with it.
onefiveight
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2/14/2018 3:13pm
Amazing. I will have one, I must lol
Lol.. Yeah... It's pretty nice. If you decide to pull the trigger on one, hit me up and I can save you a LOT of time...
Lol..
Yeah... It's pretty nice. If you decide to pull the trigger on one, hit me up and I can save you a LOT of time trying to get started with it.
Thanks man I will!
bf884
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2/14/2018 4:35pm Edited Date/Time 2/14/2018 4:36pm
After pricing them out I’m going to attempt to build my own. And excuse the 1st grade doodle drawing, but in theory it should work. Keep up the good work.

Sandblaster
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2/14/2018 5:01pm Edited Date/Time 2/14/2018 5:03pm
Yep... That should work..
The pump puts out only a couple of gallons a minute (Guess).
Run 15% Glass to 85% water
Stainless steel is best.
If not, you might want to consider heavy plastic.
Mild steel will rust away rapidly.
Put a light inside and some petals on the floor.
One petal to control the air, and one to squirt fresh water on the glass.
Put a piece of small 1" x 1" channel under the glass so when you squirt the glass with fresh water it will drain and not go into the tank. Otherwise you will constantly be having to add glass or drain excess water.
You may also want to put a easy to clean screen or filter over the pick up for the slurry pump.
Oh yeah... You will need some sort of low volume fan to blow the vapor out of the tank... Vent it to outside of your work area.
Sandblaster
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2/15/2018 1:31pm
Wow! TuBliss really makes a nice set up.
I've never used these before but will give a detailed report after all the testing is done..
Thank you TuBliss!!!!



Sandblaster
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2/20/2018 8:24am
Here we go..
Some really nice wheels from Faster USA
http://www.fasterusa.com/
951.600.7048
sales@fasterusa.com
FasterUSA
38435 Innovation Ct #105
Murrieta, Ca, 92563

Wait a minute... Green hubs..... For a KTM???
Oh Yeah!!!
Faster USA did a special run for this build and I couldn't be happier with how they turned out...

And check out those rims... Excel made good by donating some A60's... Beautiful...
http://www.rkexcelamerica.com/
(760) 732-3161
RK Excel America Inc
2645 Vista Pacific Drive
Oceanside, CA 92056











171Ondra
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CZ
2/20/2018 12:51pm
Nice project . kx engine is amazing and green frame awesome :-)
Sandblaster
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2/20/2018 8:28pm
171Ondra wrote:
Nice project . kx engine is amazing and green frame awesome :-)
Thanks!
I hope it turns out in the end how it is starting Woohoo
Sandblaster
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3/9/2018 8:36am Edited Date/Time 3/9/2018 8:37am
Ok... It's been a while since I last updated this thread.
The reason for that is I ran into a issue on my beautiful cone pipe.
Because this was a long distance one off project you have to be prepared for such things...
Anyhow, I pulled the fork caps off to allow the suspension to fully compress. Everything looked great until I tried to turn the bars to the right...



The interference was about 2" Shocked

So..... My first thought was.. If your suspension is fully compressed and your steering it turned, likely you are going down anyway... But then I thought... What about damage to the pipe?
So out came Mr. Sawsall and a cutoff wheel Dry



Oh the feeling, to cut up your beautiful pipe...
Once I had it all fitting correctly I tack welded it up, boxed it, and shipped it back to the pipe builder..
I sent him pics as I went along to be sure that I didn't make any more serious mistakes Laughing

It should be done and back to me in a couple of weeks Cool

In the long run it would have been cheaper and less expensive to send him the frame, forks, wheel, and engine cases and let him properly build the pipe. Oh well.... He can make it purdy again.... I hope Blink
onefiveight
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3/9/2018 1:10pm
Thanks for the update, been having withdrawals.
Byron909
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Round Rock, TX, USA
3/10/2018 8:41am
Neat bike. I put a 500 honda in a 15.5 450sx chassis few years back, i have cc forks on my bike, so running 20mm offset clamps. At full compression my tire hit my chamber, just barely. I removed about 1/4" from the head tube after flange and it was golden after that. Looks like your kawi chamber is needing alot more!
Those big 2 strokes in these modern ktm chassis are awesome. You get the suspension right, you probably wont want ride anything else!
Sandblaster
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3/10/2018 3:04pm
Byron909 wrote:
Neat bike. I put a 500 honda in a 15.5 450sx chassis few years back, i have cc forks on my bike, so running 20mm offset...
Neat bike. I put a 500 honda in a 15.5 450sx chassis few years back, i have cc forks on my bike, so running 20mm offset clamps. At full compression my tire hit my chamber, just barely. I removed about 1/4" from the head tube after flange and it was golden after that. Looks like your kawi chamber is needing alot more!
Those big 2 strokes in these modern ktm chassis are awesome. You get the suspension right, you probably wont want ride anything else!
Cool.
I wanted to use a 450 chassis but I used what I could get.
Post some pics of your conversion, I'd love to see it.
FiendzCC
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3/10/2018 5:07pm
Damn, your heart probably dropped when you realized you were gonna cut into that pipe haha. The wheels look clean, I had fun building them
Byron909
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3/11/2018 12:51am Edited Date/Time 3/11/2018 1:05am
Here are some pictures. My frame was a ktm race team frame from the '15 sx season. I got it around june '15, but all I had was a bare frame and swing arm, and my engine. At that time only the fe models were out, so getting parts was not happening. I waited till mid december to get a 16 125/150 tank, radiators, airboot, and some misc hardware particular to the new frame. Yeah, just getting the swingArm bolt took 3 months. Ihere is the frame as i got it.



One of my main reasons for building this bike, is that im tall, 6"5'. I have a 450 ktm with a lift kit deal from 2 tall racing. Makes me fit on a bike like the average 5'8" guy does. Im just too big for a honda. So i fit the ktm perfect, but wanted my 500.
Anyway, here are a few photos. Whether trails, mx, etc it rips. I built the motor years back, originally pulled from a dumpster back in '98, in as bad of shape as a engine could be. This frame is now its 4th and final home.



























Laced up a 2.50 rear. Hooks good.




Its a very simple bike, conversion wise. Not much weird on it. I have kawis and hondas ive converted that have a ton of fab stuff, one off to that bike sorta thing. This ktm is not like that. I only made one change to the radiators, te hoses are just 16 up 125/150 for the most part. I put all my electronics under tank. Nology coil, cdi. Allowed me to hack up the upper airbox tray. No problems with air.
I got carried Away with the ti. At first it was just to get rid of the honda bolts. In the end everything but axles and linkage was ti. I wasnt worried about weight, but in its mx trim it came in at 227. But man it feels much lighter on stand and in motion. Very flickable. With the xc tank, 18 rear its about 3 lbs more before fuel.
I have a 99 300 ktm im partial to, so am slowly building this bikes' clone, but with my old 300 engine.

Those centercases on your bike are pretty awesome.
Sandblaster
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3/11/2018 5:29pm
FiendzCC wrote:
Damn, your heart probably dropped when you realized you were gonna cut into that pipe haha. The wheels look clean, I had fun building them
It was definitely a sobering moment taking that first cut but I've done dumber things in my life Lol..

On building my wheels... You are the man... Those are really sweet wheels.
I can't wait to get them on the bike... but I'm just not quite ready yet..
But who knows, I may do another mock up when the pipe get's back Cool

Hopefully we will be down your way this summer for the MXA testing.
When we do you should come to the track and take it for a spin after MXA get's done with it. Woohoo

There is a reason they call those guys the Wrecking Crew Laughing
Sandblaster
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3/13/2018 9:47pm
Byron909 wrote:
Here are some pictures. My frame was a ktm race team frame from the '15 sx season. I got it around june '15, but all I...
Here are some pictures. My frame was a ktm race team frame from the '15 sx season. I got it around june '15, but all I had was a bare frame and swing arm, and my engine. At that time only the fe models were out, so getting parts was not happening. I waited till mid december to get a 16 125/150 tank, radiators, airboot, and some misc hardware particular to the new frame. Yeah, just getting the swingArm bolt took 3 months. Ihere is the frame as i got it.



One of my main reasons for building this bike, is that im tall, 6"5'. I have a 450 ktm with a lift kit deal from 2 tall racing. Makes me fit on a bike like the average 5'8" guy does. Im just too big for a honda. So i fit the ktm perfect, but wanted my 500.
Anyway, here are a few photos. Whether trails, mx, etc it rips. I built the motor years back, originally pulled from a dumpster back in '98, in as bad of shape as a engine could be. This frame is now its 4th and final home.



























Laced up a 2.50 rear. Hooks good.




Its a very simple bike, conversion wise. Not much weird on it. I have kawis and hondas ive converted that have a ton of fab stuff, one off to that bike sorta thing. This ktm is not like that. I only made one change to the radiators, te hoses are just 16 up 125/150 for the most part. I put all my electronics under tank. Nology coil, cdi. Allowed me to hack up the upper airbox tray. No problems with air.
I got carried Away with the ti. At first it was just to get rid of the honda bolts. In the end everything but axles and linkage was ti. I wasnt worried about weight, but in its mx trim it came in at 227. But man it feels much lighter on stand and in motion. Very flickable. With the xc tank, 18 rear its about 3 lbs more before fuel.
I have a 99 300 ktm im partial to, so am slowly building this bikes' clone, but with my old 300 engine.

Those centercases on your bike are pretty awesome.
I love what you did with the Honda engine. You did the exactly how I'm gonna do mine.. I'm gonna really watch my temps carefully. Kawi's can be finicky...
That height kit is awesome.. Probably gives you some much needed room... Although mine isn't all that tight.
All I can say is beautiful bike... Nice build. I hope mine comes out as nice..
Sandblaster
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3/16/2018 4:32pm
I was so desperate for a aluminum right exhaust valve cover that I was going to have these pieces water jetted from 1/4" aluminum, glue them together with aluminum adhesive, then sand and polish.... Thank you TSR from saving me from myself Lol..



Thank you TSR!!!

Byron909
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Round Rock, TX, USA
3/16/2018 4:40pm
Thanks for the compliments.

Thats trick. Always wanted that in aluminum for my kxs, do they make them, or is that part a one off?
DPR250R
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3/16/2018 6:56pm
Byron909 wrote:
Thanks for the compliments.

Thats trick. Always wanted that in aluminum for my kxs, do they make them, or is that part a one off?
Holy shit that bike is nice... what was it like to ride?
Sandblaster
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3/17/2018 7:47am
Byron909 wrote:
Thanks for the compliments.

Thats trick. Always wanted that in aluminum for my kxs, do they make them, or is that part a one off?
I have 10 left after just a few days of receiving my first batch of 40. but no worries, when these are sold out I will be getting 20 more. If you want one they are 68 USD delivered anywhere in the USA. Send me a PM with your email address and I will send you a invoice through PayPal. IF you are out of the USA let me know where and I will get you a quote.
Sandblaster
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3/17/2018 7:49am
Byron909 wrote:
Thanks for the compliments.

Thats trick. Always wanted that in aluminum for my kxs, do they make them, or is that part a one off?
DPR250R wrote:
Holy shit that bike is nice... what was it like to ride?
I'll let you know hopefully in a few months when it is done Laughing
I'm still waiting on parts for the engine as well as a few other things...

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