Rolling Chassis

I’m currently getting the rolling chassis completed, as I have a small man-shed and there are currently parts everywhere.

So far –

  • frame and subframe have been cleaned, blasted and resprayed satin black
  • welded up the side stand hole and redrilled it, blasted then painted satin black
  • swinging arm cleaned, blasted and new bearings fitted
    • stock is single bearing and o-rings which is crap, I fitted 2 sealed bearings each side plus an extra seal on the exposed side
  • rear wheel – rebuilt with new hub, spoke nipples, seals and bearings
    • gallery below shows using a blow torch, gentle heat, and internal bearing puller, makes removing bearings a pice of cake
  • airbox stripped and cleaned – issues with captive nuts – for another day!
  • rear caliper rebuilt plus new piston – I use an airline on low pressure to pop pistons out
    • ktm 28mm piston was very expensive at £40, and my local dealer was out of stock, did some measurements and bought a brembo car caliper piston for £9, same part,  wtf?
  • new brembo ceramic rear pads
  • rear master cylinder rebuilt
  • new rear brake line fitted
  • new rear mudguard fitted
  • new rear light fitted
  • new side panels fitted
  • front forks rebuilt – new bushes and seals – picture shows using long socket and ratchet to hold the fork leg when doing the bottom bolt up
  • fork yokes blasted
  • headstock bearings replaced
  • new lockstop plate
  • new renthal fat bars
  • new throttle
  • new renthal grips
  • front wheel cleaned – new bearings and seals
  • front brake caliper rebuilt
  • stainless bleed nipples fitted to front and rear calipers
  • new stock dash bought and fitted
    • bargain deal, but kmh speedo, but sourcing a 60mm alternative is proving tricky
  • Polisport MMX headlight and spacing brackets fitted
  • ufo supermoto front mudguard fitted
    • junked the CCM cable guide and fitted a plastic ktm one. required spacers – plastic 10mm OD x 5mm h x 6mm ID
  • started cleaning carbs – wtf – how much chain do you need to use!