2005 ATC450R Aluminum Frame

[audioworks04]

Some of the guys I met at Trike Rampage requested me to post up some build pics of my 450. Remember I am a poor college student so all of my materials are not the best, but they are what I could afford at the time. I am currently in the process of doing inverts, but I do have alot of resources which is what allowed me to do what I have done. I purchased each part individually as I was able to afford it and took almost a full year to build. There is alot of pre-planning and tig welding involved in this build and is not for the average Joe, no offence.
2005 CRF450R frame
2005 CRF450R motor
41mm FCR Carb with NCVQ needle and R&D power pump II
1986 ATC250R forks and triple tree....for now
1985-1986 ATC250R air box and intake
Custom one off subframe
Custom seat from trx and crf
CRF450X tank and shrouds
2004-2005 TRX450R swing arm, pegs, rear fenders, rear brake, axle, sprocket
custom sub frame
billet rear shock mount with peps sprung and re-valved 400ex shock

So here they are.....
http://i597.photobucket.com/albums/tt59/audioworks04/travisatc450r.jpg
Roller
http://i597.photobucket.com/albums/tt59/audioworks04/DSCN0521.jpg
http://i597.photobucket.com/albums/tt59/audioworks04/DSCN0528.jpg
Rear shock mount from 3" solid 6061 aluminum tube
http://i597.photobucket.com/albums/tt59/audioworks04/DSCN0618.jpg
Motor Shipped
http://i597.photobucket.com/albums/tt59/audioworks04/DSCN0601.jpg
Reinforced lower frame rails and peg mounts
http://i597.photobucket.com/albums/tt59/audioworks04/DSCN0423.jpg
Pretty uni-cam motor...have to remove both side covers and cam cover to install into frame.
http://i597.photobucket.com/albums/tt59/audioworks04/DSCN0605.jpg
http://i597.photobucket.com/albums/tt59/audioworks04/DSCN0604.jpg
R&D Power Pump II
http://i597.photobucket.com/albums/tt59/audioworks04/DSCN0644.jpg
Pivot bolt issue....one of the largest obstacles to over come
http://i597.photobucket.com/albums/tt59/audioworks04/DSCN0422.jpg
Subframe
originally tried to use a trx450r aluminum subframe, but broke it 3 times and got fed up with it so built my own.
http://i597.photobucket.com/albums/tt59/audioworks04/ATC450R%20Subframe/DSCN0968.jpg

Some Videos
http://i275.photobucket.com/albums/jj314/stallbaumer5/th_Threewheelerwheelies.jpg (http://s275.photobucket.com/albums/jj314/stallbaumer5/?action=view&current=Threewheelerwheelies.flv)
http://i275.photobucket.com/albums/jj314/stallbaumer5/th_MorningJumpRuncut2.jpg (http://s275.photobucket.com/albums/jj314/stallbaumer5/?action=view&current=MorningJumpRuncut2.flv)
action=view&current=Mar10_LS.flv]http://i275.photobucket.com/albums/jj314/stallbaumer5/th_Mar10_LS.jpg[/URL]

[audioworks04]

http://i597.photobucket.com/albums/tt59/audioworks04/ATC450R%20Subframe/DSCN0934.jpg
http://i597.photobucket.com/albums/tt59/audioworks04/ATC450R%20Subframe/DSCN0961.jpg
http://i597.photobucket.com/albums/tt59/audioworks04/ATC450R%20Subframe/DSCN0960.jpg
http://i597.photobucket.com/albums/tt59/audioworks04/ATC450R%20Subframe/DSCN0959.jpg
http://i597.photobucket.com/albums/tt59/audioworks04/atc450rsand.jpg
http://i597.photobucket.com/albums/tt59/audioworks04/atc450rwheelie.jpg

[250sx]

GREAT job. I was trying to talk you out of it when you showed up at the group pic. :D Tell me again what you had to do for the triples?

[disco]

I'd love to have something like that. I lack the money for the TPC, and the fab skills to do it myself.

[RapidRick]

Nice work, :hail: wish I could do that

[audioworks04]

The triples are fairly straight forward. Use the atc250r upper and lower triples and press out the stem, then mill the lower and upper to accept the 450r stem (this is the expensive part). You also have to remember that the atc triples have rake built in, so you will gain some rake. Mine is currently 1/2 degree more rake than a stock 86 atc250r. I am using the 2005 frame which has alot less rake built in than the previous years crf. My whole front set up will be forsale as soon as I get my new triples for my inverts.
As far as the money.....dont let this fool you I may be a poor college kid, but I have way more wrapped up in this than I thought I would and stopped counting because it was getting scary.

[250sx]

You should really look into seeing what it would cost you to offer some "kits" for this project that would include just the custom conversion-related stuff that people couldn't buy directly off a trx or crf. You might be surprised at the interest depending on the price. I think the kits out there now are all around $3k.

[audioworks04]

I have heard from many that I should offer a kit, the complexity here is that there is alot alot of tig welding involved in the process, making it very hard to offer a kit. But if anyone needs some help or direction I am very willing to answer any questions.

[Mr. Richard]

VERY NICE!! i am glad to see people get out and DO IT!! looks like you had a plan , i really like the aluminum frame too...

[crackshot]

Where did you get those cool fork boots?

[audioworks04]

www.sealsavers.com

[lsra_atc250r]

Thanks for posting the pics! Looks great!

[Duner]

looks very good. :headbang:

[reddigan]

i was just curious, would you be able to do this with a cr250, would the parts match up the same?

[audioworks04]

Not sure if the parts would match up the same, but I am sure that it could be done. Not very many bolt on parts at all most are weld on. I believe that the cr frames have alot more rake built into the neck which would make the triple set up different than just throwing on an atc set such as I did. It has been done before awhile back by someone on here, but dont remember his name.

[reddigan]

i think i know who yours talking about, he made his own custom triples and swinger i think. but yea im kinda curious cause in the future i kinda wanna do my own conversion. im 16 as of now and was hoping of getting a list of parts now so i wont have trouble finding stuff later when i get my job

[audioworks04]

parts list will all depend on how you want to do it. If i could do it all over again, I would start will a complete bike and go from there. I would build my own swinger and have some triples made for me, the tpc setup is amazing. I actually rode his 450 conversion and its handling and suspension is unbelievable, also it should mount right up to the cr and crf frames.
One of the hardest things to figure out is the rear shock mount and air box setup. I would probably try and get the cr rear shock re-sprung and valved for your new setup.

[Ol Deuce]

:cool: You did a great job on your build , its always good to see the finished
product! Ol Deuce

[ikilla2]

Nice work buddy, I'm glad you posted this as I'm just about to convert a TM250 2stroke to a trike.

I'll take pics as I do it.

[Tecate 50]

Jason Hall on 3wheelerworld is possibly who you are thinking of in reference to the triples! He made my triples for inverts on my 85 Tecate!

[audioworks04]

I have talked to jason about his triples and thought about ordering a set, but for what you get it really seems rather expensive. I also strongly disagree with this single bolt design on the triples. Every fork has torque numbers just like any other bolt and if you over tighten them it can cause damage and limit travel. I would be much more friendly to a dual bolt design.

[3on3250-R]

Audioworks, It takes quite a few machine shop hours to do everything to make up the complete kit, thats not Including Material. My clamps are not just hillbilly drilled, they are set up on a machine, drilled, tapped, and bored. I don't make hardly anything on the clamps, the machinist makes all the money! If I drilled tapped and bored them In my vise by hand the price would be much less. If thats how I did thing's then people would have miss alighned bolt holes and not have a simple bolt on Kit. I have jumped the HELL out of my 450, also dropped off a 12 foot cliff at Gordon's well 2 years ago. My clamps have not Budged one bit!!! Mine are 3/4 of an Inch thick. The one's I sell are 1" thick. IMO the only reason Stock 450-250-125 clamps have 2 pinch bolt Is because the material around the clamps Is less than 1/4" thick!!

http://i237.photobucket.com/albums/ff42/Jasons450r/triples2.jpg

A single bolt will put some SERIOUS clamping force on the the fork tube's without coming close to the max torque spec of the bolt!! It would take STUPID amounts of flamping force to limit travel on any fork. The biggest thing to remember Is triples work together, top and bottom.

http://i237.photobucket.com/albums/ff42/Jasons450r/Tripledrawing.jpg

Have a look at the clamps Kasey found from a Very heavy streetbike which has a single bolt straight from Honda.

http://i237.photobucket.com/albums/ff42/Jasons450r/VTXtriples2.jpg

My clamps are on 8 bike's now, and soon to be more without a single problem where they clamp to the forks. I would say they have been pretty damn well proven!!

[Goat]

Now jason, you go using logic and reason and you're just gonna confuse everyone lol.

[audioworks04]

I was in no way saying that your work is sloppy or poor quality, sorry if you took that wrong. I do see your point in the thickness of your clamp over that of an oem cast clamp. I would probably order a set of your right now if I wasnt buying a house and building a GMC Typhoon.......

[no_doz]

outta curiousity why spend the time & money doing something so awesome when titanium tubing can be purchased at a price that isnt drastically higher?

always wanted to do so myself, but i cant justify going 3/4 the way without saying screw it & go with the titanium.

if you think im full of it & that titanium (tubing) is like building it out of $100 bills, i can give you links to some suppliers that have some pretty damn reasonable prices considering how much good aluminum costs & how strong titanium is.

plus, who the hell wouldnt want THOSE bragging rights?


with all of that being said, this thing looks gorgeous!!

[350xsx]

Audioworks, It takes quite a few machine shop hours to do everything to make up the complete kit, thats not Including Material. My clamps are not just hillbilly drilled, they are set up on a machine, drilled, tapped, and bored. I don't make hardly anything on the clamps, the machinist makes all the money! If I drilled tapped and bored them In my vise by hand the price would be much less. If thats how I did thing's then people would have miss alighned bolt holes and not have a simple bolt on Kit. I have jumped the HELL out of my 450, also dropped off a 12 foot cliff at Gordon's well 2 years ago. My clamps have not Budged one bit!!! Mine are 3/4 of an Inch thick. The one's I sell are 1" thick. IMO the only reason Stock 450-250-125 clamps have 2 pinch bolt Is because the material around the clamps Is less than 1/4" thick!!

http://i237.photobucket.com/albums/ff42/Jasons450r/triples2.jpg

A single bolt will put some SERIOUS clamping force on the the fork tube's without coming close to the max torque spec of the bolt!! It would take STUPID amounts of flamping force to limit travel on any fork. The biggest thing to remember Is triples work together, top and bottom.

http://i237.photobucket.com/albums/ff42/Jasons450r/Tripledrawing.jpg

Have a look at the clamps Kasey found from a Very heavy streetbike which has a single bolt straight from Honda.

http://i237.photobucket.com/albums/ff42/Jasons450r/VTXtriples2.jpg

My clamps are on 8 bike's now, and soon to be more without a single problem where they clamp to the forks. I would say they have been pretty damn well proven!!

Whats the cost

[Mr. Richard]

outta curiousity why spend the time & money doing something so awesome when titanium tubing can be purchased at a price that isnt drastically higher?

always wanted to do so myself, but i cant justify going 3/4 the way without saying screw it & go with the titanium.

if you think im full of it & that titanium (tubing) is like building it out of $100 bills, i can give you links to some suppliers that have some pretty damn reasonable prices considering how much good aluminum costs & how strong titanium is.

plus, who the hell wouldnt want THOSE bragging rights?


with all of that being said, this thing looks gorgeous!!


OK I WANT TO KNOW WHERE TITANIUM TUBING WOULD BE USED IN A FRONT END????? AND it might be reasonable to buy,, BUT working with titainum ,, you need a clean room, all the fab tools have to be titainum only as to eliminate any contamination!!! thats the expensive part,,, building a frame could run in the 10's of thousands just to build it,,,,,

[Mr. Richard]

Every fork has torque numbers just like any other bolt and if you over tighten them it can cause damage and limit travel.

i have heard this many times ,,, and i am going to say remember the science class experiment??? you take the strongest guy in class and give him an egg,, putting it in the palm of his hand and ask him to break it,,, with even pressure all the way around,,, it can't be done...

same thing on forks.. the clamps will hold the forks in place with a fraction of the force needed to actually crush the housing,,, i don't think its possible with aluminum clamps,,, i don't think it could be done with even 2 bolts,, i am sure you would be talking about hundreds of tons of force... i say its scare tactics on someones part,,,

here is a pict of both clamps i got,, these are from a honda street bike that has a dry weight of 750 lbs!!!! so a 280 pound trike should have NO WORRIES ,,,,

http://i50.tinypic.com/35kr6fp.jpg

[350xsx]

well i could use a set of those if you're sellin em 3On250R, i was just going to take a trip to the waterjet and machine shop guy and talk to him about it.

than again, Kasey, those are clamps from a factory streetbike and they work alright with rake and everything what size forks do they fit
Let me know
Kyle