Everything has been going pretty smoothly. The bike is at the welder now to have the mounts welded in place. I am supposed to meet him early tomorrow morning to give him guidance on what goes where. I have more pics in my gallery (hybrid gallery).
The first pic below shows all the parts from ebeck. Here I am washing them. I don't like working with dirty parts.
The first step was to cut off the old KX mounts. I cut them off with a air cutter. Bought it Harbor Freight for $10. Worked great.
Next I ground off the old welds and then sanded the frame rails smooth. For this I used a 4" grinder and sandpaper. This pic shows the frame ready to grind.
The next job was to modify the swingarm. The long bushing in the swingarm has to be shortened and the swingarm has to be shortened (narrowed) the same amount. I shortened mine 9mm. These pics show the swingarm marked, in the process of cutting and the the finished product. I cut them a little long and then went to the finished length with a grinder. I made them really smooth with a belt sander and then a light hand sanding. As I was cutting I would continually stop and check with a digital caliper to make sure I was still on track and not veering off course.
After that I had to enlarge the hold in the rear of the cases from 15mm to 17mm. This turned out to be the hardest part of the job so far. I thought it would drill easily...NOT. This stuff ruined three bits. After that was done I was able to bolt everything together and start working on the mounts. The bottom mounts came from the KX, they just had to be shortened a little. The front mounts came off the KDX. It was almost an exact fit. I them hooked the pipe up and test fit it with the rads and airbok on. I then made some hangers for the pipe. Actually I stole them off the KDX frame also (along with the motor guard loops). The following pics shows everything bolted in place and ready for the welder.
More pics to come.
