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Rappa racing in Italy uses a lot of 3D printed airboots for their builds
https://www.instagram.com/reel/DFiR16IMMxh/
So when I clear coat them I either use duplicolor hi temp engine enamel clear coat or VHT makes a good hi temp as well. Usually lasts me all season with maybe an extra little touch up once or twice but stuff holds up well.
No big updates like I thought gentleman, had to work this weekend and didn't really have time. My 125 airboot is supoose to come in today and between today and tommorow hopefully gonna have this airbox together with the new boot. Won't really be able to test fitment till motors back in the bike so I'm just fingers crossed it fits like few good reputable ppl told me it does.
I would much rather have an air boot that's a bit longer rather than one that's too short!
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Copy. I was not aware of that.
Alright so finally got the 125 airboot in. It is a little different, seems like it has more of a curve to it, explains why few ppl said it's little longer but works. Might be a wrestling match, well see 😅Modified the airbox to fit the aluminum mxbonz sealing rings and chopped off the old rubber locator nubs and used his hardware. Just a test fit to make sure it fit together now just gotta seal it up good. Would like to have bottom end together this weekend as sounds like my cylinder is already done. Guess I'll see this weekend how the boot fits too if I get the motor built and back in the bike.




I have been using this stuff to seal my airboxes at the boot/box junction, takes a while to setup but once it does, appears strong & flexible. Maybe worth a try on the original boot, prep is everything

Very cool thank u for heads up ! Ill grab some of that tommorow. Was thinking something like this between boot to airbox and then going over the outside edge with clear silicone. I'll definitely try it out on my 250 boot kinds wanna have a backup in case this 125 boot idea thing doesn't pan out
Clean the rubber boot with soap & water, then rubbing alcohol first, this product is gas/oil safe so it has been working good on sealing my air box to boot junctions.
Did u use nu car wax with silicone sprayed in it. Then wax the inside of the boot 3 times? Twin air alum power flow cage it works . You should get that.
Hung out in garage tonight with my pops and put the bottom end together. New pro x main bearings and seals, oem crank and cometic gaskets. Everything went smooth. Hoping to have cylinder back this week but till then gonna get my clutch back in, kicker gear and spring, inside clutch cover etc on then put the completed bottom end back in the bike. One more step to being a complete bike !

So little update, turns out the 125 airboot works! However it is difficult to get the boot onto back of the carb. Easy way to cheat it is just put the boot to back of carb so you can manipulate it little then bolt the airbox back to the subframe. Definitely make having carb on and off a pain but works. Luckily this keihn pwk I can get to the pilot and main through the bowl nut so it's all good.

Also got the bottom end back in the bike. Just got my cylinder back from millennium from replate so gonna assemble the powervalve back into the cylinder and get this motor finished next. Starting to bolt on some stuff, think I'm actually gonna use the oem style front plate keep it more oem kinda look. Bought some protaper platform pegs so bike will feel like my 02, similar bar bend, same pegs, gearing etc between the two.
After motor is done next thing I'm gonna go after is putting correct Shock spring on for my weight and focus on addressing the wheels since has few loose spokes, put some tires on. And just overall button this thing up. Least kinda looks like a bike again.

The Bill's Pipes look legit bolted on👌my 2007 cr250 I did.


Bike looks sweet I love their cone look pipe. Be between that and a PC pipe when it comes time to replace the fmf I have right now.
Got my engine bolt kit, love this company's stuff. They've probably gotten thousand bucks from me over the years just with their pre dilled washer kits 😆 This made motor pop little more. Also took my reed cage back out cause I only fit it the other day to make sure my 125 airboot would work. So threw new reed cage bolts at it, new gasket and tightened it all down. New brake pivot bolt too old one was hurting. Put some more plastic on so it'll look like a bike again and put it next to rest of the fleet. Starting to give me some motivation to get this together.


Spent little time on the cr today. Got the motor buttoned up. Cylinder, piston and head on. Radiator hoses all on and some re routing of stuff. Pipe and silencer on, new air filter in. Filled the gear oil and coolant. Holding off on pv cables cause mine are frayed and I'll have new ones in few days. By next weekend I'll finally be able to try this thing.



Pit Row
Looking good! That CR250 fired up and is ripping. Solid progress getting her put back together.
I have a mint silencer, graphic set, stock sprocket cover.
Looking for the other nos parts i have in my dozens of parts bins
I raced all the 2002-2007 CR250's
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Small update. Decided to use my wheels from a 09 crf450/cr250 build and put my clapped wheels on the 450 to roll it around. Will eventually build the wheels but this will get me through for bit. Never liked black rims and wanted to keep that stock look so this worked good. Besides that I added some drilled washers, red axle blocks, anti seized the adjuster bolts and found 1 of mine completely hogged so gonna have to drill and tap that. Gonna put those pv cables on this weekend and least break it in. From there then new tires, seat cover, backgrounds etc
Checked all spokes, rims don't have flat spots so I proceeded to baking soda the wheels. Thing works great on hubs and spoke/nipples. Can see the difference on left side I blasted vs right side even brought back the finish on the rotor bolts.
Little side not why I've been slacking finishing my 06 is cause I've been riding this 02 that me and dad built together and been dialing in jetting, suspension etc. Things a blast, just PC pipe, 304r silencer and jetted the mikuni and runs very strong but kinda signs off, may try the longer PC silencer next. After learning all the differences between an 02/03 to a 05-07 while building I'm curious how they're gonna feel back to back or if I'll notice much at all 🤔

Happy 4th gentleman. Little update with this thing. Got around to getting the throttle jockey seat cover on, new PC r304r silencer and went back to black wheels and some black fatbars. Other bars and silver wheels are going on another 2000 build, sold a 2000, bought another and pocketed some money. After riding my 02 I've decided to sell this 06 when it's done too. I'm sure this will be a great bike but have enough 2 strokes in my fleet and wouldn't mind a 450 to go racing on.
As for things left to do, I need to rebuild the front brake caliper, fuel peacock leaks, blow out dent in the pipe and lastly put an oem silver clutch cover on it. Did start it and she runs crispy. Also rebuilt the rear caliper too, came out pretty good
Here's my 03' I've been working on. I was going for an OEM+ kind of look and I have a few things to finish up. Since these photos, I added new lower fork guards, and new tires. Next I want to switch out the pipe with a raw finish pipe. It has an FMF shorty on it, but I may go to a PC pipe or the Bill's cone look pipe.
That things sweet! Very nice 03 dude 🤘
I got around to rebuilding the front caliper and bled brakes, put a new oem petcock on, oem shifter and took it for a rip. She barks!
Just gotta blown dent in pipe out/clean it up more and give it a good check over and things ready to rip.
The worn off boysen bronze cover was irking me so I bought a hinson cover for it, damn these covers are sweet.
What are you rebuilding on the caliper ? Don’t you hv a 2-st class in Ma. ? Last yr it was the biggest class aprox 28 especially on the sand tracks in Wi. Did you use the hrc method for adjusting the pv ? I do on my 04 125. Dremel a paper thin amount of the hole out . That the pv shaft goes in. Polish the rollers on the pv shaft too. You can get the pv operating soo smooth. A gear high in whoops or set rollers it hits & rips real quick , less chassis disruption than blasting on the mid range . I wish I had a 06 I woukd get the PC MC spec porting .
Yeah I can see a little bend in the 125 boot. I,m going to try & find a 05-07 250 boot yet for my 125. Some Honda parts are not avail on there site . Sometimes they are on a diff site. I use Service Honda the parts are the cheapest. Remember Steve from pulp show Gopher dunes vid 2nd corner a cr250 had the lead . Wicked mid bark . 2 yrs ago Surratt won a moto against 300,s.
So I put in new caliper pistons, seals and media blasted the caliper. Thing came out really good. Then bled the system. Brakes came to life instantly. Huh never heard the dremel trick but I did polish the pv shaft, kinda had to cause was little crusty. Thing absolutely barks to attention, definitely snappier then my 02 with the stock mikuni.
Took it for it's first real ride and damn this things fast 😳 Very impressed by its low to mid hit, it's almost little to much. Think I prefer my 02's soft power delivery to this things low end hit. Gonna go smidge bigger on main jet but other then that things ready to ride. She is gonna be for sale next week or so but gonna do few more things but it's minor stuff.
If anyone is intrested in buying this, I work with a local bike shipper who can bring it anywhere within the US. This how she looks currently![]()
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