Custom Stems

Questions and comments about converting to beefier forks..

Custom Stems

Postby T-Roy » 11:26 am Dec 07 2005

Howdy Fellas!

Well, to make a long story short, the deal on my KDX fell through (I was selling out :sad: ), so it looks like I'm going to keep her after all :cool: . With that being said, I'm now going to go ahead and complete my KX front end conversion. No better time than Christmas to spend some more cash on the 2-honey...

I have a 01 KDX and a set of 03 KX TT's. I would love to have a custom stem desinged and manufactured for my conversion. Is this something that would be worth my time pursuing? I personally don't know a machinist and noticed that Phil was one! Phil, would you be willing to take on a project such as this? I'm willing to pay accordingly, unless you feel that the process would be cost prohibitive.

Any thoughts or ideas are greatly appreciated.

Man, it feels nice to be back in the game again. :supz:
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Postby Indawoods » 11:45 am Dec 07 2005

Welcome BACK! :supz:
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Postby KDX220PHIL » 11:49 am Dec 07 2005

Glad to hear you decided to keep the bike, she's a beauty!

As far as pay goes, I will not do it for profit, I would glady take on any challenges relating to this. Do you get snow there? Is the bike put away for the winter? I am first going to tackle my setup, and if it works I would like to send a stem to someone so they can check to see if it works on the US model. If so, I would like to get hold of other years TT's and make the stems to convert each year. At that point I can either send you a stem and you can have soemone press it in, or you can send your TT to me and I can press it in. Even better if we can figure out a way to restrict the rotation (discussed in previous threads and solution underway) a press fit is not necessary but, a very close tight toleranced fit without machining to TT (woodruff key would be nice). I guess we should look at the cost of shipping a TT and see what options we have.
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Postby Indawoods » 11:56 am Dec 07 2005

A Woodruff key would wear the aluminum... a roll pin or two would do the trrick though... like KDXr's Aussie bike.
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Postby KDX220PHIL » 12:02 pm Dec 07 2005

Yeah it would, but the principal works. Any pics on this roll pin?

You could drill and tap a hole through the front of the TT and screw in pin that would locate inside an oblong hole in the stem. Unfortunately, the whole idea was avoiding modifications, although anyone with a drill and tap could do this one, and these threaded locating pins are easy to get, for me anyway, could come with the stem.

I am just tossing around ideas, feel free to contribute.

Reason for the oblong hole is that the up and down location of the stem should not be controlled by the pin, just the rotation.
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Postby Indawoods » 12:12 pm Dec 07 2005

Not really... look at the stem at the bottom of the pic... you can make out the pin...

Image
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Postby KDX220PHIL » 12:17 pm Dec 07 2005

Am I blind??? I don't see it! :? Is it that darkish spot that look slike a suff?

*EDIT* Looks like a scuff.
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Postby Indawoods » 12:23 pm Dec 07 2005

Yup...
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Postby KDXer » 12:48 pm Dec 07 2005

Here's the grub screw that replaced the roll pin. It is a better option to a roll pin because it can be removed very easily.

Image

KDX220PHIL wrote:Am I blind??? I don't see it! Confused Is it that darkish spot that look slike a suff?


That spot is the hole that the roll pin / grub screw goes into. It is just a basic everyday hole drilled about 2mm deep. Here's a dodgier picture for ya. And what's a 'suff' ??

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Postby KDX220PHIL » 01:14 pm Dec 07 2005

My idea exactly!!!!

KDX'R- I meant "Scuff", haha.

Does evryone's TT's come with this hole? I will have to check mine when I get home on Friday.
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Postby KDXer » 01:47 pm Dec 07 2005

Nope I believe I am primogenial or numero uno. :shock: In other words "NO" I think I'm the only lucky one. :rolleyes: :mrgreen:
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Postby canyncarvr » 02:20 pm Dec 07 2005

Why bother making a stem? Just for the fun/challenge/neatoh-ness of it?

Just curious about it is all.

The fit of the KDX stem into the KX clamps isn't a problem. There are some things good to know about it...but those things have already been noted on this forum.

I bet you'll really like the KX setup! It's a treat to ride!!

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Postby KDX220PHIL » 02:45 pm Dec 07 2005

The whole purpose of this project:

To avoid modifying any parts that would result in them being useless as their original purpose. The Kx parts can still fit a KX and the KDX parts will still fit a KDX.
This may come in handy if one wants to sell their bike and the buyer does not like the idea of non-stock suspension ( what do they know anyway).

To make it easier for installation/removal of the parts. The tripple tree can be assembled/disassemble without the need of pressing the parts in and out.

The Kdx setup would remain in tact, although the KX stem would need pressing out at first and would require pressing back in if KX TT needed to be returned to stock. KDX setup coud be re-mounted wihtout visiting a machinist.

Cheaper than purchasing another KDX stem, knurling, and pressing.

Weight, hahahha, under 1 lb. I bet if aluminium is used.

And of course, for me anyway, the fun, the challenge and the neato-ness right-onness of it all.
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Postby Indawoods » 02:52 pm Dec 07 2005

Here's my thoughts......

I sold my KDX forks and wheel to recoup most of the cost of the conversion.

And "B" :wink: I wouldn't sell my KDX to someone who couldn't appreciate all the mods and love I have put into it! :mrgreen:
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Postby KDX220PHIL » 02:55 pm Dec 07 2005

What about the 1 lb. weight difference??? :rolleyes:

This way you could sell your TT too!
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Postby Indawoods » 03:02 pm Dec 07 2005

Actually, I sold the top clamp that will work for 89-92 KDX's to m0rie so he could have rubber mounted bar with adjustment instead of the solid non-adjustable mounts.

And the bottom I could sell to you to melt down and make a 1lb stem! :mrgreen:
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Postby m0rie » 03:04 pm Dec 07 2005

>|<>QBB<
Indawoods wrote:Actually, I sold the top clamp that will work for 89-92 KDX's to m0rie so he could have rubber mounted bar with adjustment instead of the solid non-adjustable mounts.


Which works absolutely bitch'n btw.
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Postby Colorado Mike » 09:05 pm Dec 07 2005

Phil,

If you want to try making an '03 stem, I can send you my '03 KX 125 triple tree.
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Postby KDX220PHIL » 05:14 am Dec 08 2005

Yeah that sounds like a good idea Mike, T-roy's TT is the same year also so you may be able to split the shipping cost, unless he is wanting to ship his TT also, but it may be cheaper to have a shop press out the old one and have me ship the piece (s) afterwards.

I will keep you updated on my setup, once it is completed I will gladly do both of yours.

I personnaly think the easiest way to do this is make several stems that work for your TT and if anyone wants that stem I can ship it to them. They can then have the old one pressed out and blah-blah.

I'll PM you my Postal Code so you can get an approx. figure for shipping, make certain it is worth it to you.
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Postby Indawoods » 06:03 pm Dec 08 2005

Phil,
are you going to make these out of steel or aluminum?

If aluminum... what grade? And hollow or solid billet?
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