Go Back OFN Forums > Fabrication > UTV/Buggy Fabrication

UTV/Buggy Fabrication For all those doing your own fabrication on the Yamaha Rhino and other UTV's


UTV/Buggy Fabrication For all those doing your own fabrication on the Yamaha Rhino and other UTV's

Reply
 
Thread Tools
  #1  
Old 12-28-2012, 12:54 PM
fiveota's Avatar
fiveota fiveota is offline
Fabricator
 
Join Date: Nov 2008
Posts: 38
Project GSX-Raptor 600 - Build with photos and video

You guys interested in seeing the build of my 01' Raptor 660 powered GSXR 600? Started in April, finished in August so there's alot of photos and some video
Reply With Quote
  #2  
Old 12-28-2012, 02:37 PM
Defender Chassis's Avatar
Defender Chassis Defender Chassis is offline
Master Fabricator
 
Join Date: Nov 2006
Location: Mid-Ohio Valley
Posts: 410
Duh.............











Of course, what are ya waitn' on?
Reply With Quote
  #3  
Old 12-28-2012, 04:28 PM
fiveota's Avatar
fiveota fiveota is offline
Fabricator
 
Join Date: Nov 2008
Posts: 38
Quote:
Originally Posted by Defender Chassis View Post
Duh.............

Of course, what are ya waitn' on?
An invitation of course

With that said let the photo post whoring begin

This story goes like this - My buddy started taking me on weekend trips to ride quads in the sand dunes in exchange for helping on some of his 4x4/car projects.
Originally he had an 02’ raptor 660.

He purchased a blaster so he had a second quad, and myself or his nephew could ride that. I used to ride dirtbikes back in the day and I still ride streetbikes.

Quads in the sand are a who-notha’ level of fun (mad tv reference).
After a few trips he decided to upgrade to a raptor 700 and I got to ride the 660.
Much better.

After a guys trip earlier this year with 6 quads and three dirt bikes outfitted for sand ….

One of which is a FZR600 carbed banshee.





I got back home and decided it was time to build... not buy, a ride for myself.
I searched craigslist and cycletrader, every good deal was gone within hours.
I found a quad with a blown motor which was just perfect for me since I wanted to bore and stroke the motor to a 686 or 727.

I picked up this 01’ 660 for $500.00 and it came with 75% of a second motor.

I got it back to a friends house until I could figure out how to tell my wife that I purchased a quad without talking to her about it, while in the middle of my big GS300 build…



Reply With Quote
  #4  
Old 12-28-2012, 04:33 PM
fiveota's Avatar
fiveota fiveota is offline
Fabricator
 
Join Date: Nov 2008
Posts: 38
Start dismantling it in said friend’s garage







At this point I had been doing research for a few weeks and decided on which parts to go with.

The supporting mods for the original parts would require larger carbs and other supporting mods to make it reliable. Carbs are simple, but I look at them as difficult....

Im an EFI and wiring guy. I would rather hit the go button and… well… go.

My friends were trying to talk me into a streetbike conversion and I kept saying no.

While looking over the carcass at my buddies house we started to realize the quad had a bunch of aftermarket parts on it. Most of which I didn’t care for. A ghetto supertrapp muffler. A hydraulic clutch conversion… the bug hit me.

If I sell off all these crappy parts, and buy gaskets to build one good motor, I could sell the 660 motor and pay for some of the parts I would need for whatever direction I go.

My friends were sending me craigslist ads of other quads and streetbike motors.

I ended up looking as well...peer pressure is a biotch...found a guy parting out his race bikes/trailer etc.
He had a spare motor from the previous season and wanted to clear everything out of the garage.
I assembled a stock 660 motor, sold it for $400 within two days and used that money toward this impulse buy of the K7 gsxr 600 FI motor.

I didn’t want to do an R1 motor because I don’t feel that I need that much power on a quad. Too much is almost enough you say… true story but not a necessity in this case.
Reply With Quote
  #5  
Old 12-28-2012, 04:34 PM
fiveota's Avatar
fiveota fiveota is offline
Fabricator
 
Join Date: Nov 2008
Posts: 38
Got the motor home and quickly realized there was zero hope of getting the motor to live in the frame without mods.



I’ve done tons of motor swaps and other crazyness but never worked on a chassis.

If I know one thing, its that once you cut the frame and it springs out of place – your hosed.
So I set out and learned about jig’s a little.
For the purpous of this home brew quad, I built my own frame jig with steel frame and wood platform up on sawhorses.





I thought what the hell you only live once, so after a lot of measuring and test fitting I make the first cuts on the frame.



Reply With Quote
  #6  
Old 12-28-2012, 04:35 PM
fiveota's Avatar
fiveota fiveota is offline
Fabricator
 
Join Date: Nov 2008
Posts: 38
My buddy was sand blasting some parts while I screwed around with the frame



This obviously won’t work



The beginning of some front upper motor mounts to triangulate the frame



Trouble shooting the torchmate while cutting some parts for the mounts



To make these



Reply With Quote
  #7  
Old 12-30-2012, 11:23 AM
fiveota's Avatar
fiveota fiveota is offline
Fabricator
 
Join Date: Nov 2008
Posts: 38
This was the first time I’ve tig welded steel. After some recommendations from a friend. I picked up a gas lens and got a little better at welding. Came up with this



For here



And here



With a jig to install them straight



A little fishmouth with a tube notcher





End result is left and right mounts





Mockup with cardboard then draft and cut some more mounts




Last edited by fiveota; 12-30-2012 at 11:27 AM.
Reply With Quote
  #8  
Old 12-30-2012, 11:29 AM
fiveota's Avatar
fiveota fiveota is offline
Fabricator
 
Join Date: Nov 2008
Posts: 38
Lower motor mounts with a full weld so that tabs don’t just break off



Test fit to a lower tube which ended up being removed later



Some rear upper mounts which will have the upper shock mount incorporated into it.



Repurpose the original upper shock mount







Reply With Quote
  #9  
Old 12-30-2012, 11:30 AM
fiveota's Avatar
fiveota fiveota is offline
Fabricator
 
Join Date: Nov 2008
Posts: 38
After deciding to fabricate a air box over the ITB’s I decided to reinstall the upper frame.
I sleeved the upper frame rails



At this point I needed to figure out wtf I was going to do with the lower frame.





The oil pan is so damn deep on the K6-K7 motors that I needed to build the chassis around the motor.
I broke the rule of removing the frame from the jig.
Though on the same token, that’s partially what the jig is for, to be able to put everything back as it was. Which it did, all of the parts I had mocked up still fit perfectly after I reinstalled them.

Getting pretty stoked by this time







With the frame being wider, I needed to inboard the foot pegs.
Again with the carboard mockup, draft, cut and fab



Reply With Quote
  #10  
Old 12-30-2012, 11:36 AM
fiveota's Avatar
fiveota fiveota is offline
Fabricator
 
Join Date: Nov 2008
Posts: 38
If im going to build this thing, its going to be overbuilt, opposed to being thrown together and/or underbuilt as most of these conversions are that I’ve seen.













Tacked into place and mocked up



Once they were done I realized my brake pedal was all jacked up so I started hacking and patching the old one till I got it to fit right.



The look at it and said fawk this. Im not going to half ass this biotch. Drafted up a new one and built it from scratch



Nice fit

Reply With Quote
  #11  
Old 12-30-2012, 11:37 AM
fiveota's Avatar
fiveota fiveota is offline
Fabricator
 
Join Date: Nov 2008
Posts: 38
At some point in the build, I figured since this was a street bike conversion I should ditch the crappy levers off the quad and get some bitchin adjustable pazzo knockoffs on some gsxr pedestals.

It would have been easier to have a whole bike than to have to keep buying parts off auction sites but in the end im really happy with the total cost of the project and how it turned out.







SICK !

I’m thinking “Sh1t this is gonna feel like im on my 750 !”



Reply With Quote
  #12  
Old 12-30-2012, 11:39 AM
fiveota's Avatar
fiveota fiveota is offline
Fabricator
 
Join Date: Nov 2008
Posts: 38
Still getting rid of parts on craigslist, I saw a guy looking for a stock muffler for a 660.

I emailed saying I had a supertrapp I would let go cheap.
He said he had an FMF titanium and would I be interested in trade + cash. I said sure, grabbed a $20 even though I want this to be a straight across deal, and met up with him local venue.
He explains that every time he goes out, he gets stopped with the DB meter on the sand (we always do as well, but we test ok) no matter how much packing his friend puts in the muffler…

I show him the supertrapp and he pulls the FMF out with $40.00 ! I lol to the bank
The old POS



The winning new one



And I lol’d more when I looked down the bore and saw this – Two pieces of expanded mesh as the “spark arrestor” and the “packing” was steel wool from end to end… WTF



At some point a while back my ankle started hurting like a mofo, but being a guy I just said fawk it.
It’ll grow back… till I stepped off a curb and felt shooting pain up my spine.
Thought “sh1t I should prob listen to the wife and get this *ish checked out”

They found a couple of bone fragments that look like they may be the cause…





In fact that may be why…



Moving on… the stock 32hp 660 engine on these short wheelbase 660’s is already a problem.

That would prove even more problematic when you add a 124hp 600cc 4 cyl into the mix 

So I decided on and built a 8” swingarm from scratch

Mocking it up just to see if I like the length before I built a jig for the arm







Gotta have a chain guide so I don’t kick that sucker off and wrap it around a body part




Last edited by fiveota; 01-04-2013 at 03:00 PM.
Reply With Quote
  #13  
Old 12-30-2012, 11:40 AM
fiveota's Avatar
fiveota fiveota is offline
Fabricator
 
Join Date: Nov 2008
Posts: 38
The stock front shocks on these 660’s feel like you’re on a hay wagon with the spring on a stick pogos.

So my buddy Eric that takes me on these trips picked up these piggyback semi-remote res YFZ450 shocks



When you’re installing the remote res shocks on a rappy, expect mods.
Some people just notch out the lower control arm. I wanted to build new mounts and beef up the uppers to ensure they’re not going to rip out when im ripping over the wash boarded trails.

Ground off the stock mounts



I cut these with the TM and bent them with a oxy torch





Welded those bishes on

Reply With Quote
  #14  
Old 12-30-2012, 11:41 AM
fiveota's Avatar
fiveota fiveota is offline
Fabricator
 
Join Date: Nov 2008
Posts: 38
Then for the upper mounts, I didn’t want to hack more of the frame off so I opted to reinforce it by adding tabs on the outside.

Notching the inside and cutting some inserts to weld in.









This is how she’ll sit



I was board one night and decided I wanted to put the ignition switch where the reverse switch was originally.

So I cut a few of these and viola



Reply With Quote
  #15  
Old 12-30-2012, 11:42 AM
fiveota's Avatar
fiveota fiveota is offline
Fabricator
 
Join Date: Nov 2008
Posts: 38
I was pretty stoked to receive this baby in the mail. Gonna be pretty sweet seeing the tach fly up and the sound of the motor singing as I sail past the thumpers.

Its true they’ll get me with torque…



I cut the tab off the cluster and mocked up a bracket in cardboard to mount it to the steering stem.

The bracket cut in aluminum



Turned out just the way I wanted. I can see it in the day, and at night. In the glare of the sun, you can still see it for the most part

Reply With Quote
  #16  
Old 12-30-2012, 11:44 AM
fiveota's Avatar
fiveota fiveota is offline
Fabricator
 
Join Date: Nov 2008
Posts: 38
The problem I mentioned previously about how low the oil pan sat… I looked at doing a drysump with a flat pan. Too expensive.

I looked at some of the pans for guys that stunt the bikes. Still not low enough.

I cut down the pan to be a height I could live with and reworked the oil pickup.





Welding skills need improvement but it’ll hold



Then for extra measure I wanted a skid pan, and like everything else I made it heavy and over built x10

Cardboard mockup



Cut in steel



Then I figured, what the heck, why not build something BA and combine the zuki/yam logos and make my custom deal





Tabs so I can unbolt it in the front and back.
I know, more ugly welds. (I was a little overzealous because I was so stoked, I didn’t take enough time to tig these. I busted out the hot glue mig gun)

Reply With Quote
  #17  
Old 12-30-2012, 04:46 PM
fiveota's Avatar
fiveota fiveota is offline
Fabricator
 
Join Date: Nov 2008
Posts: 38
Since the stock abs fuel tank was nowhere near fitting and I wanted a large tank with an intank pump, it was time time to start mocking up an aluminum tank.

I saw a two piece factory filler neck from a skidoo that I thought would work well so I could keep the starndard ATV filler caps.

Here’s the cardboard version



And the aluminum version so I can bend it around under the plastics and make sure it all fits







I want to run a gsxr fuel pump to make this all relatively pnp. I found these weld flanges online

Reply With Quote
  #18  
Old 12-30-2012, 05:04 PM
fiveota's Avatar
fiveota fiveota is offline
Fabricator
 
Join Date: Nov 2008
Posts: 38
After doing some more mockup I decided I was going to need to change strategy on the filler neck.

Having the two piece was a novel idea, but how would I replace the gasket or service it.

This became more apparent when the fuel pump flange arrived, as I couldn’t fit my hand thru the hole.

I searched high and low and could not find an aluminum filler neck to accept a standard atv cap.

But I did find some aluminum ones for seadoo’s.
This one came from blowsion.





I cut a new top plate for the tank that would allow the filler neck to sit at the same level as the plastic one once folded and welded.
This way I can weld the two together and not worry about leaks.



This is the first time I got to see her as a roller.

I messed with the spring rates on the ITB’s so I could use a streetbike throttle cable, but with the ATV thumb throttle.
I don’t like twist throttles offroad.



This is a full resto mod as well since the quad sat outside at the previous owners house.

The headlight housings were faded. I cleaned them up with dishsoap and water.
Then used “trim black” rattle can. I love that sh1t.



It goes on thin enough to show all of the factory texture. Its flexible so it won’t peel or flake off.



(A little skip ahead so you can see one cleaned up)

Reply With Quote
  #19  
Old 01-01-2013, 10:51 PM
Joe Llamahead's Avatar
Joe Llamahead Joe Llamahead is offline
Master Fabricator
 
Join Date: Apr 2009
Location: Port Orford Oregon
Posts: 125
Looking good so far..... Thanks for posting all the pictures and all the info. Reminds me of the quad Z project my son Tony and I did together. It's. TriZ 250 engine and swing arm in a blaster ,he did the hybrid name plate thing too.
Reply With Quote
  #20  
Old 01-04-2013, 08:26 AM
CarterKraft's Avatar
CarterKraft CarterKraft is offline
Master Fabricator
 
Join Date: Oct 2009
Location: DFW
Posts: 845
Nice work on the quad, looks great.

And great work on the build thread, I just realized that over the holidays I completed several projects and I can't produce a single thread for any of them.
Reply With Quote
Reply

Bookmarks


Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump


All times are GMT -4. The time now is 08:08 AM.

Powered by vBulletin® Version 3.8.0
Copyright ©2000 - 2017, Jelsoft Enterprises Ltd.
Template-Modifications by TMS
Copyright ©2012, Offroad Fabrication Network