1993 Doug Henry tribute build - raffle proceeds to benefit Road 2 Recovery

TooOld4WFO
Posts
672
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4/1/2018
Location
Fresno, CA, USA
4/20/2021 7:26pm
Looking great. I bought my ticket. If there are 99 more left I should just buy them all. That bike would be worth the $10,000.00 no doubt. It’s that serious of a restore.

As for the front brake line routing. Man I didn’t realize how much more involved just to use those protectors would be.
Your line appears to have a different end mating to the caliper.
When you asked that question on routing I just assumed you would route it like Honda did with the factory bikes. Little did I know the difficulty in seeing an image of how they did it.
You can find loads of works Honda’s with those protectors on. Most have disc covers on the left side. Those few without like Bayle’s images is a right side shot only. I even checked out Terry Goods site for some guidance.
This was the only image I could find.



They are using some kind of metal cover over where the line comes through at the bottom. It appears to be routed over the top of the axle to the inside.

Aaron what must I do to get a brake line like yours?
1
aaron0000834
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139
Joined
12/28/2016
Location
New Haven, VT, USA
4/20/2021 7:49pm Edited Date/Time 6/11/2021 6:57am
TooOld4WFO wrote:
Looking great. I bought my ticket. If there are 99 more left I should just buy them all. That bike would be worth the $10,000.00 no...
Looking great. I bought my ticket. If there are 99 more left I should just buy them all. That bike would be worth the $10,000.00 no doubt. It’s that serious of a restore.

As for the front brake line routing. Man I didn’t realize how much more involved just to use those protectors would be.
Your line appears to have a different end mating to the caliper.
When you asked that question on routing I just assumed you would route it like Honda did with the factory bikes. Little did I know the difficulty in seeing an image of how they did it.
You can find loads of works Honda’s with those protectors on. Most have disc covers on the left side. Those few without like Bayle’s images is a right side shot only. I even checked out Terry Goods site for some guidance.
This was the only image I could find.



They are using some kind of metal cover over where the line comes through at the bottom. It appears to be routed over the top of the axle to the inside.

Aaron what must I do to get a brake line like yours?
Thanks Matt, hopefully I can sell them all and meet the goal I've set to raise funds for the Road2recovery.

I actually robbed the brake line off my 99 rm250, it routes down and under the front axle. Its the only option the other three had thanks to Honda's brake line patent. I did strip the outside skin off the line to make it more flexible.

Here are some pics Luke Hibberd shared with me.



3
aaron0000834
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139
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12/28/2016
Location
New Haven, VT, USA
4/27/2021 7:23am Edited Date/Time 5/22/2021 3:56am
Working some magic on the left engine case, cut, weld, cut, sand. It came out looking pretty tight, now to get them Cerakoted gloss black.

Hit me up for raffle tickets, PM or email eightthreefourmoto@gmail.com
New website www.eightthreefourmoto.com






7
Badoo
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97
Joined
7/23/2018
Location
Greeley, CO, USA
4/27/2021 9:23am
Wow! Just wow
2

The Shop

aaron0000834
Posts
139
Joined
12/28/2016
Location
New Haven, VT, USA
4/28/2021 3:45am
Badoo wrote:
Wow! Just wow
Thanks Badoo, we're in the home stretch now!!
aaron0000834
Posts
139
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12/28/2016
Location
New Haven, VT, USA
4/28/2021 3:49am
We almost have a roller, the front wheel is laced and ready to go!





4
TooOld4WFO
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672
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4/1/2018
Location
Fresno, CA, USA
4/28/2021 10:12pm
Aaron on that front brake line. You mentioned something about Honda and a patent.
Would this mean I could not have a line made?
My plan was to simply use a\some plastic tubing to mimic the line and the route I want to take it. Than add that distance to an existing line measured from the top of the axle retainer going up to the master cylinder.
From that measurement just have a line custom made to work with the Nissan master cylinder and caliper.
aaron0000834
Posts
139
Joined
12/28/2016
Location
New Haven, VT, USA
4/29/2021 4:23am Edited Date/Time 6/11/2021 6:58am
TooOld4WFO wrote:
Aaron on that front brake line. You mentioned something about Honda and a patent. Would this mean I could not have a line made? My plan...
Aaron on that front brake line. You mentioned something about Honda and a patent.
Would this mean I could not have a line made?
My plan was to simply use a\some plastic tubing to mimic the line and the route I want to take it. Than add that distance to an existing line measured from the top of the axle retainer going up to the master cylinder.
From that measurement just have a line custom made to work with the Nissan master cylinder and caliper.
Hey Matt, that's definitely an option and a good plan!! The patent I mentioned was the front brake line routing, Honda held a patent from before I can remember to 2005ish. The patent gave Honda an advantage with a shorter brake line routing, this forced the other Japanese manufacturers to route the brake lines below the axle. The longer brake line equaled a loss in fluid pressure and gave a spongy feel at the lever, so they say. Funny thing is the patent stated inverted forks, so from 96 to 98 when Suzuki ran conventional forks they ran the line just like Honda. Anyway, you can definitely use some tubing and route it as you'de like and then have a custom cable made to that length.
1
aaron0000834
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139
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12/28/2016
Location
New Haven, VT, USA
5/5/2021 7:09am Edited Date/Time 6/11/2021 6:58am
Spent some time this weekend getting the bottom end together, a coat of fresh gloss black Cerakote really brought this engine back to like. Unfortunately I'm going to split the case again to find out why the sprocket shaft has lateral play... I ordered some the thrust washers and spacers to make sure I have all the parts this time. That's the fun part about these builds, you never know what's missing until you need it, haha. The parts list keeps growing, also new crank outer bearings, Hot Rods crankshaft, transmission bearings, all shaft seals. She's gunna be tight! Looking forward to getting her built and listening to her sing!





5
jettech6622
Posts
23
Joined
4/26/2021
Location
Houston, TX, USA
5/5/2021 8:53am
After seeing the level you have gone to ...i want to start over on mine...Smile
aaron0000834
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139
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12/28/2016
Location
New Haven, VT, USA
5/5/2021 11:26am
After seeing the level you have gone to ...i want to start over on mine...Smile
Thanks man, shoot your 86 builds are beautiful 😍
1
jettech6622
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23
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4/26/2021
Location
Houston, TX, USA
5/5/2021 12:52pm
Was just talking to the owner of the 500...sent him your build...he is with me..we are pulling all the factory bolds plates springs and axles and having them plated...looking at your bike thats the details missing from the 500.
aaron0000834
Posts
139
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12/28/2016
Location
New Haven, VT, USA
5/5/2021 8:35pm
Was just talking to the owner of the 500...sent him your build...he is with me..we are pulling all the factory bolds plates springs and axles and...
Was just talking to the owner of the 500...sent him your build...he is with me..we are pulling all the factory bolds plates springs and axles and having them plated...looking at your bike thats the details missing from the 500.
That will be a nice touch on an already excellent bike build. Make sure to polish the bolts before plating to get the rust pits and scratches out, it will make for a better end result. 👍
aaron0000834
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139
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12/28/2016
Location
New Haven, VT, USA
5/6/2021 11:14am
Man what a work of art.
Thanks KiwiBermRailer, all for a good cause!
aaron0000834
Posts
139
Joined
12/28/2016
Location
New Haven, VT, USA
5/22/2021 4:01am
Back at it finishing the build, only two weeks left to MX rewind at Unadilla. Today I finished the Bill's pipes replica silencer. Its actually an 05 YZ125 can with the CR hanger welded in place. Spent a little time filling some old wear marks in with weld and smoothing it all out with a nice brushed look. Repacked it with some Moose racing fiberglass packing. Can't wait to hear this thing bark!!

I stopped in the Lynks racing to pick up the old cylinder, I needed it to finish mocking up the exhaust. Gregg talked to Mitch at Pro Circuit about a new cylinder and Mitch had one stashed away with some port work already done. The cylinder is going to show up sometime this week. Man this bike is going to rip!

Raffle tickets available www.eightthreefourmoto.com or eightthreefourmoto@gmail.com











2
5/22/2021 6:03am
I love this build. When it's all done you should post about the raffle in the moto related section. It will get a lot more traffic there.
1
5/22/2021 7:40am
Insane attention to detail.
2
aaron0000834
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139
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12/28/2016
Location
New Haven, VT, USA
5/22/2021 11:07am
I love this build. When it's all done you should post about the raffle in the moto related section. It will get a lot more traffic...
I love this build. When it's all done you should post about the raffle in the moto related section. It will get a lot more traffic there.
Great idea, l'll definitely do that!! 👍
sandman768
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8195
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3/21/2014
Location
Saratoga Springs, NY, USA
5/22/2021 5:47pm
Silencer looks mint👍.... turn the petcock around so the on/off is facing inward...
2
aaron0000834
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139
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12/28/2016
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New Haven, VT, USA
5/23/2021 3:56am
sandman768 wrote:
Silencer looks mint👍.... turn the petcock around so the on/off is facing inward...
Thanks man!! Will do, have to put the oring in there too
aaron0000834
Posts
139
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12/28/2016
Location
New Haven, VT, USA
5/23/2021 4:26am Edited Date/Time 5/23/2021 4:27am
Absolutely stoked on the front number plate, Thank you Phil and Tom for doing the leg work to get this autographed!!! Also a huge Thank You to Doug Henry for signing it!!





Tickets available here www.eightthreefourmoto.com or email eightthreefourmoto@gmail.com

Just using the old cylinder to mock up the exhaust. Pulled the bike out of the moto cave and into the garage to be closer to the work bench and tools. Only two weeks until the unveil an MX Rewind!!



The air filter may be the only part from the original bike that didn't need any work. Well I suppose I washed it and re oiled it, but thats just typical maintenance.


6
shawski
Posts
42
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9/22/2018
Location
Elk River, MN, USA
5/23/2021 4:35pm
Great work, I bought a ticket. Probably end up buying some frame guards later if I don’t like my plastic UFO ones.
2
aaron0000834
Posts
139
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12/28/2016
Location
New Haven, VT, USA
5/23/2021 6:19pm Edited Date/Time 5/25/2021 6:15am
shawski wrote:
Great work, I bought a ticket. Probably end up buying some frame guards later if I don’t like my plastic UFO ones.
Thanks for supporting the build and R2R!!!
2
aaron0000834
Posts
139
Joined
12/28/2016
Location
New Haven, VT, USA
5/27/2021 3:59am
Feeling the crunch the last couple days trying to get this bike together for MX rewind!! I'm also a little worried I'm not going to reach my ticket sales goal... If any of you are on the fence or may know someone who might be interested please share with them. I'd like to pull the winning ticket at MX Rewind but also want to raise as much as possible for Road2recovery.

I split the cases again over the weekend and fixed the output shaft, it was missing two washers and the wrong spacer for the sprocket. All the lateral movement is gone. Installed a new Hinson clutch basket with new clutch plates, feels like butter.




If you guys are looking for OEM carb hose you can get this stuff on Amazon. Its enough to do three or four bikes and won't break the bank.

Finally swapped the media back over in my wet blast cabinet and got the rear caliper blasted. All rebuilt with new pads.



5
GrapeApe
Posts
9001
Joined
6/7/2010
Location
Mc Kinney, TX, USA
5/27/2021 8:11am
I love this build. When it's all done you should post about the raffle in the moto related section. It will get a lot more traffic...
I love this build. When it's all done you should post about the raffle in the moto related section. It will get a lot more traffic there.
Great idea, l'll definitely do that!! 👍
I may have missed it, but you definitely need to post this in the moto-related section. You'll sell the remaining tickets by the end of day.
4
quiknic
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844
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11/30/2008
Location
Santa Clarita, CA, USA
Fantasy
5/27/2021 8:38am
shawski wrote:
Great work, I bought a ticket. Probably end up buying some frame guards later if I don’t like my plastic UFO ones.
Thanks for supporting the build and R2R!!!
Love the build, your attention to detail and the cause! (3) more tickets purchased from my end. I also purchased the Todd DeHoop jersey from R2R a few months back and it has been killer to see his progression and drive.

1
aaron0000834
Posts
139
Joined
12/28/2016
Location
New Haven, VT, USA
5/27/2021 11:51am
quiknic wrote:
Love the build, your attention to detail and the cause! (3) more tickets purchased from my end. I also purchased the Todd DeHoop jersey from R2R...
Love the build, your attention to detail and the cause! (3) more tickets purchased from my end. I also purchased the Todd DeHoop jersey from R2R a few months back and it has been killer to see his progression and drive.

Thanks for the support Nick!!! That Jersey is beautiful 😍
aaron0000834
Posts
139
Joined
12/28/2016
Location
New Haven, VT, USA
5/27/2021 11:55am
GrapeApe wrote:
I may have missed it, but you definitely need to post this in the moto-related section. You'll sell the remaining tickets by the end of day.
Excellent Idea!!! I've buttoned her up for some money shots, still have some more work to do though
Kenny Lingus
Posts
1088
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9/9/2016
Location
Watkins Glen, NY, USA
5/29/2021 11:16am
GrapeApe wrote:
I may have missed it, but you definitely need to post this in the moto-related section. You'll sell the remaining tickets by the end of day.
Excellent Idea!!! I've buttoned her up for some money shots, still have some more work to do though
He's right. I had no idea about it until I saw it in moto.
1

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