'07 dirtbag CM400 build

[PBR Allstar]

Okay, decided to start chopping today for the Dirtbag challenge. Got the frame squared away on Cyclones jig and started cutting, got the backbone replaced which was kind of a chore seeing as the original structure on the CM400's was a stamped and welded mononcoque style frame, I had to do some creative fashioning at the rear vertical tube, but it's in, I should have more photo's following in the next couple days (the tank is just tywraped to the frame for looks at the moment)

[spencer75]

holy shit man, you're not using exhaust tubing for the frame are you? that wall looks mighty thin...I'm not second guessing your work, it might just be a bad camera angle

[swinewerx]

see you there

[PBR Allstar]

Originally Posted by spencer75

holy shit man, you're not using exhaust tubing for the frame are you? that wall looks mighty thin...I'm not second guessing your work, it might just be a bad camera angle

probably a bad cameral angle, the backbone tubing is 1.750" x .095" wall seamless DOM tubing, I figure it's plenty strong seeing as the stock backbone was stamped 1.5mm (.063") steel..

[El Shawn]

PBR, Looks good, that's exactly what I did with my CM. seems to be holding up just fine. So far. knock on wood.

[Cyclone]

Looks great! Let me know if you need anything.

[PBR Allstar]

Okay, bent up all the tubing for the back half today while I was at work as well as tuned up the stock axle plates (we have an 18" disc sander, makes easy work of shaping plate). So when I got home the first order of business was putting in the 1.5" x .120" wall horizontal tube for my lower tubes to mount up to, these slipped snuggly over some stock spuds that were in the same location so I was able to rosette weld them and weld the inboard perimeter as well, I will probably gusset them later. Next on my agenda was wraping my shaped axle plates with 1" x .120" steel to give something for the new back half tubes to mount to. I figured this was a bit easier than trying to tie the tubes directly into the axle plate by slotting them and swedging them down by hand, plus, I think it should look pretty nice once I make some scalloped gussets connect the tubes and the axle plate. With that taken care of it was on to the fun part, connecting the dots with 1" x .095" wall DOM tubing and watching my new +4" back half take shape!!! Both the bottom tubes were pretty straight forward, but the two down tubes,,,, man, those are a bit tricky to get just right! Tack, measure, break tacks, trim, tack, measure,,,, it went on about two more times.. but I eventually got it to my liking and the tubes were level all the way from the back bone to the axle plates (I'd like to know how the pro's do that part). Anyway, here are some pics, next will be to fab up some gussets to tie everthing together and Tig all the joints. I think I'll be on track to have it out of the jig by weeks end.

[Halseth]

Looks damn good. I cant wait to see it done and in person

[PBR Allstar]

Thanks Halseth, yeah,, it should be a good show! I put a few HEAVY tacks on it this morning, crossed my fingers, and released it from the jig, Nothing went "TWANG" and the engine mount bolt slid out easily so today I'm going to work on some gusseting and finish welding. Then on to the long list of ancillary items to deal with. I'm pretty stoked though, I'm up to just a little over 500 dollars total on the build including the taiwanese ebay tank, seat, levers, controls, bars, and the 300 dollar cost of the bike.

[image1]

looks great, keep it movin and keep us up to date

[Fred Aemmer]

Looks great Can't wait for more pics.

[sweatmachine]

you gonna give it to that cute girl when you're done?

[PBR Allstar]

So today after I got home I was planning on finish welding all the joints, which, I was successful at. After that I "was" planning on cutting out the frame gussets, but, I deceided I needed a bit of a boost as far as my vision for the project goes, so I grabbed the rear well, slammed the forks on it, cut up the stock handle bars and made something a little more to my liking (those are just temporary at the moment but I kinda dig them so I may go back and clean them up and tig weld them) rolled it outside and there ya go! It looks way better than I imagined! Although I was planning on using my stock controls and just modifying them a bit,,, but I've now decieded I don't think that is going to be a possiblilty, so new foot controls are going to be on the agenda as well!! I might not get to work on it tomorrow, seeing as we have to do the trick or treating gig, but I'll update soon.

[PBR Allstar]

One other thing I forgot to mention, I'm sure other people do it as well, but, if you're like me, and don't have a good tubing bender in your garage, and have to go over to the shop your buddy works at on his lunch break to bend tube and dont want the job to take any longer than is absolutely necessary. A good way to calculate your bend angles and hopefully only have to do the job once is to use electrical conduit, it's about 2-3 bucks for a 10' stick of 1/2" and the bending die is about 15 dollars, it's easy to cut, bent and see exactally what you want before you waste expensive tubing.

[jamie desoto]

Originally Posted by PBR Allstar

One other thing I forgot to mention, I'm sure other people do it as well, but, if you're like me, and don't have a good tubing bender in your garage, and have to go over to the shop your buddy works at on his lunch break to bend tube and dont want the job to take any longer than is absolutely necessary. A good way to calculate your bend angles and hopefully only have to do the job once is to use electrical conduit, it's about 2-3 bucks for a 10' stick of 1/2" and the bending die is about 15 dollars, it's easy to cut, bent and see exactally what you want before you waste expensive tubing.

man thats a great idea!!.. i never thought about that!.. off to the electrical supply section at home depot!

[Cyclone]

Has a great stance, don't let up....you'll need a few hours to sort it out.

[PBR Allstar]

Got my registration sticker at lunch time!!!

[PBR Allstar]

got the frame gussets done, pegs done, license plate and tail light mount done, tank mounts done, forks lowered 2.5", and the engine mocked back in the frame. I really need my ebay seat to show up now so I can mount that and sort out my rear fender!!!!

[thecary]

dude, that's gonna be a cool fucking bike when it's done. challenge or not.

[PBR Allstar]

Didn't get as much done today as I would have liked, had to spend a bit of time with the family so it's going to be quite the grind this week to get everything done by sunday! I did manage to get a few things squared away though which included: mounting my brake pedal, making and mounting a battery box with some cool computer rack mounting material courtesy of Cyclone, making and mounting the link for the rear brake, finish welding my handle bars and welding the 3/4" bolts in the inner ends for plugs,,,, yeah, guess that was it for today. I really need my seat to show up, the carb isolators and throttle can wait a day or so, but let's keep our fingers crossed for the seat!!! Then I can get the frame finished off!