Hey everyone. Im new to the forum. Just recently got into minibikes but have always been into restorations, welding, engines, etc. So here's the most of my build so far.
It started off with a 5500TL atlas frame I got for free from my neighbor who had it sitting in his barn for years. It has the rear tire flipped for left hand drive, original jack shaft was missing, told me his kids used to ride it with a little 3.5 horse briggs.
I first dismantled everything, cut off the rusted seat mounting plate, cut off the tail light mounting plate, and cut off the foot pegs because they would be in the way of the new converter. SandBlasted the frame, fork, wheels, handle bars and sprocket/rear wheel.
Next I got my motor at harbor freight. 6.5 predator (on sale for $99.99!), also got a cheapy ebay knockoff comet clutch ($60.00 shipped). Did some mockup and realized the motor had to be raised up to clear the clutch plate/housing. Milled some slots in some 1 1/4" square tubing and matched it up to the factor slots and welded em in for the riser.
after getting the motor and wheels mocked up I went back to ebay to order some 5.30/4.50R6 tires and tubes to fit my wheels. First one took a while, popped one tube with the screwdriver otherwise went great. Got the seat plate mocked up and sent out toa good buddy of mine to get covered. Covering is gonna be alligator skin with silver piping to match the wheels! Plus a little dumb and dummer humor
Once I had the motor mounts mocked up with the correct height and the sprockets in line I went to working on the exhaust, front footpegs and the sissy bar. Exhaust a 1"x2" slash cut rectangle tube wrapped in header wrap! the front suspension was froze up so I cut the springs off and welded it all solid. Also, I milled a slot in some angle iron, welded a tab to the exhaust pipe for a little extra support, also needed the slot to tension the chain. Turned out great!
After finally mock up of everything I took it to my other shop to lay some paint and assemble it. Primed it up with some Omni Primer, moved onto the base coat which was 2 coats of a 2008 Pontiac vibe "Salsa Metallic" mixed with another GM red metallic red/burgandy color. After laying the base coat on the frame and fork we followed up with some PPG DX78 prismatique flake. Topped it off with a few coats of clear and called the frame good. Next was the handle bars, wheels, and foot pegs. They got a dose of a silver metallic from a 2007 Buick Lucerne I just sprayed. Had just enough for two coats. Followed that up with the same PPG DX78 and cleared it out. Not as much flake in the silver but it really POPS in the sun.
Now, onto the final assembly. Threw some new wheel bearings in with new center bushings I had machined to fit, greased em all up and threw the front and rear wheels on. Had some issues with the new bearing being to wide to fit into the frame so I stretched the frame a little with my portapower and the rear slid right in, threw the axle bolt through it, cotter pinned the nut and the rear was done. Front slid in without any major issues, did have to stretch the forks out about a 1/8-1/4 inch though. Got a quick and dirty gas (oil bottle) tank rigged up to take it for a test rip.
ran about 17-20mph according to my phone. Turned around and ripped the governor linkage off the 6.5 and bent up my own from some clothes hanger and locked the governor flapper in place.
my buddy clocked me next to his atv last night at 41-43Mph.
Still looking at a 22mm mikuni carb and a couple small performance parts.
Tank is currently getting welded up, seat should be done middle of next week,
also need to figure out a sturdy set of wheelie bars. More to come!!!
It started off with a 5500TL atlas frame I got for free from my neighbor who had it sitting in his barn for years. It has the rear tire flipped for left hand drive, original jack shaft was missing, told me his kids used to ride it with a little 3.5 horse briggs.
I first dismantled everything, cut off the rusted seat mounting plate, cut off the tail light mounting plate, and cut off the foot pegs because they would be in the way of the new converter. SandBlasted the frame, fork, wheels, handle bars and sprocket/rear wheel.
Next I got my motor at harbor freight. 6.5 predator (on sale for $99.99!), also got a cheapy ebay knockoff comet clutch ($60.00 shipped). Did some mockup and realized the motor had to be raised up to clear the clutch plate/housing. Milled some slots in some 1 1/4" square tubing and matched it up to the factor slots and welded em in for the riser.
after getting the motor and wheels mocked up I went back to ebay to order some 5.30/4.50R6 tires and tubes to fit my wheels. First one took a while, popped one tube with the screwdriver otherwise went great. Got the seat plate mocked up and sent out toa good buddy of mine to get covered. Covering is gonna be alligator skin with silver piping to match the wheels! Plus a little dumb and dummer humor
Once I had the motor mounts mocked up with the correct height and the sprockets in line I went to working on the exhaust, front footpegs and the sissy bar. Exhaust a 1"x2" slash cut rectangle tube wrapped in header wrap! the front suspension was froze up so I cut the springs off and welded it all solid. Also, I milled a slot in some angle iron, welded a tab to the exhaust pipe for a little extra support, also needed the slot to tension the chain. Turned out great!
After finally mock up of everything I took it to my other shop to lay some paint and assemble it. Primed it up with some Omni Primer, moved onto the base coat which was 2 coats of a 2008 Pontiac vibe "Salsa Metallic" mixed with another GM red metallic red/burgandy color. After laying the base coat on the frame and fork we followed up with some PPG DX78 prismatique flake. Topped it off with a few coats of clear and called the frame good. Next was the handle bars, wheels, and foot pegs. They got a dose of a silver metallic from a 2007 Buick Lucerne I just sprayed. Had just enough for two coats. Followed that up with the same PPG DX78 and cleared it out. Not as much flake in the silver but it really POPS in the sun.
Now, onto the final assembly. Threw some new wheel bearings in with new center bushings I had machined to fit, greased em all up and threw the front and rear wheels on. Had some issues with the new bearing being to wide to fit into the frame so I stretched the frame a little with my portapower and the rear slid right in, threw the axle bolt through it, cotter pinned the nut and the rear was done. Front slid in without any major issues, did have to stretch the forks out about a 1/8-1/4 inch though. Got a quick and dirty gas (oil bottle) tank rigged up to take it for a test rip.
ran about 17-20mph according to my phone. Turned around and ripped the governor linkage off the 6.5 and bent up my own from some clothes hanger and locked the governor flapper in place.
my buddy clocked me next to his atv last night at 41-43Mph.
Still looking at a 22mm mikuni carb and a couple small performance parts.
Tank is currently getting welded up, seat should be done middle of next week,
also need to figure out a sturdy set of wheelie bars. More to come!!!