Project KX: "Old School"

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Project KX: "Old School"

Postby Jason » 10:59 pm Jul 10 2012

WOW! Tough hit to take on the "new" bike!
Thank you, Julien D for all your hard work!

PLEASE! Do not "dip" PWK Keihin carbs in Berryman's to clean them! It will damage the internal o-ring (jet block gasket).
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Project KX: "Old School"

Postby Slick_Nick » 08:57 pm Jul 14 2012

What a challenge this was. The missing area was broken into about 6 tiny pieces, all about as big as a pea. I can weld aluminum with my MIG, but with pieces that small, it's a lost cause. I decided to aluminum braze them instead. I facked around with this thing for the last 3 days, and because the pieces were so damn small, trying to put it all back together around that bolt hole was a nightmare. I decided to start from scratch, and remove the bolt hole entirely. There is still plenty of support from the remaining 5 bolts, and this way I'll be able to get a nice strong corner. Brazing is often stronger than the actual base metal.

Anyways, started by cleaning it up:

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Then I cut some aluminum bar stock down and fit it in place:

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Let the brazing begin. Here the bar stock has been brazed in, and cleaned up, now the hole is filled:

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After everything was done and the cover cooled, got to work with the grinding bits:

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The inside wasn't as pretty as I had hoped, but it's strong and it wont leak!

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Final step was to mill the gasket surface flat again, and reinstall the cover. Looks factory!

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Project KX: "Old School"

Postby Jason » 09:37 pm Jul 14 2012

Congratulations on a job well done! :supz:
Thank you, Julien D for all your hard work!

PLEASE! Do not "dip" PWK Keihin carbs in Berryman's to clean them! It will damage the internal o-ring (jet block gasket).
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Project KX: "Old School"

Postby Slick_Nick » 09:16 pm Jul 17 2012

Video is uploading now, it should be live in about 45 minutes. I'm certainly not a pro, please be easy on me. It was only my 3rd ever time on a motocross track, the second time with the KX. This thing is an absolute HOOT to ride! Definitly had to "learn how to ride" all over again! It won't allow you to be lazy, you really need to work the bike! I was getting passed all night, but I still had fun, I suppose that's what really matters!

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Project KX: "Old School"

Postby Jason » 08:59 am Jul 18 2012

If you had a link to a video, I am not seing it. I clicked on your field KX125 ride, which got me to a Wild Rose (something like that) track. It looks like you had a blast!
Thank you, Julien D for all your hard work!

PLEASE! Do not "dip" PWK Keihin carbs in Berryman's to clean them! It will damage the internal o-ring (jet block gasket).
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Project KX: "Old School"

Postby Slick_Nick » 09:57 am Jul 18 2012

The wild rose video is the one from yesterday. Try refreshing your page. Both videos are displaying correctly for me.
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Project KX: "Old School"

Postby Dekon » 10:50 am Jul 18 2012

I'm not getting it either. I get your first video, but not this newer one.
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Project KX: "Old School"

Postby scheckaet » 11:14 am Jul 18 2012

your link seems fubar
02 KX 200 hybrid: RB head and carb :prayer:
DRZ 400 SM :supz:

bike build: viewtopic.php?f=111&t=8245&hilit=bike+stable
bike profile viewtopic.php?p=30709#30709

newb info: viewtopic.php?f=77&t=12457#p117919
jetting guide: viewtopic.php?f=105&t=1156
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Project KX: "Old School"

Postby scheckaet » 11:15 am Jul 18 2012

02 KX 200 hybrid: RB head and carb :prayer:
DRZ 400 SM :supz:

bike build: viewtopic.php?f=111&t=8245&hilit=bike+stable
bike profile viewtopic.php?p=30709#30709

newb info: viewtopic.php?f=77&t=12457#p117919
jetting guide: viewtopic.php?f=105&t=1156
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Project KX: "Old School"

Postby Slick_Nick » 11:17 am Jul 18 2012

Weird. The embedded video above works on both my computers AND my iPhone. Failing that, click here:

http://www.youtube.com/v/ITh7YNSw ... ature=plcp
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Re: Project KX: "Old School"

Postby KDXrider1989 » 11:25 am Jul 18 2012

That looks like a really fun track, and the bike sounds good!
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Re: Project KX: "Old School"

Postby KDXrider1989 » 10:05 pm Jul 24 2012

btw what kind of brazing rod did you use, and was it easy working with the aluminum?
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Project KX: "Old School"

Postby Slick_Nick » 11:23 am Jul 25 2012

Its very easy. CLEAN EVERYTHING well. I used Bernz-O-Matic aluminum rod and a MAPP torch.
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Project KX: "Old School"

Postby Slick_Nick » 09:23 am Jul 26 2012

Latest ride video:

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