Finally found time to share my hybrid build. It's almost finished, but I don't see many people using the 94-98 KXs, so I wanted to show how I went about it..
First, acquire derelict chassis - $60
![Image](https://scontent-b.xx.fbcdn.net/hphotos-ash3/t1/q71/s720x720/539742_10151902762095491_1850042485_n.jpg)
Next, strip super nice KDX (acquired from my friend in 2012, who was the OO since 2002)
From this:
![Image](https://scontent-a.xx.fbcdn.net/hphotos-prn1/73005_10151337595275491_461378010_n.jpg)
To this:
![Image](https://scontent-a.xx.fbcdn.net/hphotos-frc3/t1/q81/s720x720/1375101_10151951629100491_800032278_n.jpg)
Next, sell bottom end? (Still available in the Parts & Bikes forum!!)
https://scontent-a.xx.fbcdn.net/hphotos ... 8110_n.jpg
Mocked up frame and rear end.
![Image](https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-frc1/t1/q89/s720x720/998543_10151979029250491_1922895223_n.jpg)
I decided to use the entire KDX rear suspension- rocker, dogbones, shock, swingarm, everything.
First, drilling out a case is really freaking hard without good drill bits, which are expensive.
Second, should I ever want to sell the KDX engine, it will technically be unmolested. Although, I really am itching to send it off to RB to get the full monty!
Now the slightly unfortunate- while paint stripping and breaking down the KX, I noticed a sheared engine cradle tube. It was still barely attached, but I wanted to cut out the cancer and fix it for good measure:
![Image](https://scontent-b.xx.fbcdn.net/hphotos-ash3/q88/s720x720/539078_10151979029050491_1700441187_n.jpg)
![Image](https://scontent-a.xx.fbcdn.net/hphotos-ash3/q84/s720x720/644479_10151979030400491_1786323619_n.jpg)
Being a suspension engineer by day, I wanted to at least make sure the ratios in the rear were going to be *close*. Maybe not perfect, but for peace of mind, I mocked up the rear suspension of each bike in Creo, and made manipulable suspension models with sketches and proper constraints.
Here's the graphed result of the progressiveness of each setup.
![Image](https://scontent-b.xx.fbcdn.net/hphotos-ash4/t1/q71/s720x720/1489_10151979016890491_1950759670_n.jpg)
Alright, so now I know I'm going to use the KDX rear. Next step was to fab some bushings to downsize the 17mm KX swingarm pivot holes to 14mm. Word of warning, making a sturdy bushing of wall thickness (17-14)/2 = 1.5mm, or ~.060in is REALLY hard. I have years of machining experience, and it was damn-near impossible on the equipment I had (backwoods engine lathe, nichts on the accuracy...)
I patiently dremelled and sanded out the holes to about 18mm. Believe it or not, the extra .020 of wall thickness this gave me was a savior. I'm sure with a good lathe, you could make a 17mm bushing w/ a 14mm hole, but it wasn't an option for me. So here's the finished product. It's very very close to round, despite the perspective of the pic (maybe 1-2 thou out.)
![Image](https://scontent-b.xx.fbcdn.net/hphotos-frc3/t1/q77/s720x720/1424544_10151995551905491_1507223073_n.jpg)
![Image](https://scontent-b.xx.fbcdn.net/hphotos-ash4/t1/q73/s720x720/1422471_10151995551910491_1445786314_n.jpg)
With the swingarm and engine ready to bolt on, I mocked up the engine position, basically bringing it low enough for the bottom of the engine to be about parallel with the lower cradle tubes. Here are the resulting mounts:
![Image](https://scontent-a.xx.fbcdn.net/hphotos-prn1/q81/s720x720/522005_10151995551925491_1025165909_n.jpg)
And just like that, it's ready for powdercoat!
![Image](https://scontent-b.xx.fbcdn.net/hphotos-frc3/q77/s720x720/1476272_10152074571940491_1172996820_n.jpg)
![Image](https://scontent-b.xx.fbcdn.net/hphotos-frc3/q81/s720x720/1463091_10152074571935491_617820310_n.jpg)
![Image](https://scontent-b.xx.fbcdn.net/hphotos-prn2/q73/s720x720/1461091_10152074571930491_1816354601_n.jpg)
And for the past few days I've been reassembling. I was annoyed with 12 years of dirt stains on the engine, so I read up and used Eagle One Mag Wheel Cleaner- used for rough aluminum castings. It worked like a charm...
Before:
![Image](https://scontent-a.xx.fbcdn.net/hphotos-ash3/q84/s720x720/1606973_10152155232535491_542891807_n.jpg)
and After:
![Image](https://scontent-a.xx.fbcdn.net/hphotos-prn2/q71/s720x720/1505035_10152155232565491_469611848_n.jpg)
Engine in, swingarm in, front forks rebuilt and assembled:
![Image](https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-frc3/q83/s720x720/1507963_10152155232570491_947367344_n.jpg)
Just received a new OEM Acerbis plastics kit today, assembly to continue this week!