So ive been talking/brainstorming about this for a while. After really looking over the 500 frame I realize there is so much chopping I wanna do. I still want to race my bike this year soon as my motor comes back so I decided last night to use the 85 250 frame it isnt being used and is a perfect candidate for the radical idea I have for this frame. When done it will look like a normal 500. And 820 will get a stockish motor and ill find a jockey to race it in stock class against raptors and yfz's.
That's not a 85-86 frame!
Yeah it's got a wishbone in front of the cyl...
But the front shock mounts are under the frame rail.... Hmmmm
Yes it is. Look closely at the front upper shock mounts... some1 cut the single tube out and welded in a wishbone from a later year... made some progress this is basically what it will look like but the motor mount tubes will get cut out and replaced with custom chromoly motor tubes.
Ive had this frame in my garage for bout 5 years was given to me by a friend. To be honest I never realized how nice this frame is. Got the tape out and it is 1/16 out which imo is nothing and doesnt have globs of weld repairs all over it. The lower tubes have some rust pin Holes where the pegs mount. The lower tubes will be getting cut out and replaced. So here are a few mods I will be doing and also some thoughts:
chromo subframe similar to 820
Replaced lower motor cradle tubes with integrated welded on chromo drag pegs.
Reworked chromo motor mounts getting rid of the aluminum mounts tubing will bolt right to motor.
Chromo upper rear shock mount.
+6 forward bolt on ridgid front end
all ti chassis hardware
2 qt fuel tank
white/blue zilla fender.
now the thoughts:
Cutting off front end and stretching frame +6 to better match zilla frame dimensions.
reworking front upper shock mounts to later year style.
removing the single tube back bone and switching to 2 chromo back tubes to make it easier to work on.
I know not many here are interested in a drag build but I really love feedback. I love the zilla and wish it had more of a following but to be honest my bike now turns heads and draws a handful of curious patrons at the track every race when it whoops up on a 450 with 3x more money and 50 more cc's.. Makes me feel good to hear some1 say they never knew a zilla could run like that...
On my 90 Zilla, I hacked off the rear end & modified a Honda 400EX sub-frame to fit. It's all a bolt on deal. If I had to do it all over again for a dedicated drag build similar to what you are doing, I would fab up a bolt on sub-frame out of aluminum tubing. Just tig it together. That would be a substantial weight savings. Trick looking too! Keep us up to date with the progress. It's gonna be a killer ride that's for sure.
I like Drag builds!!!!! Especially ones that have lots of fab work done by the owner. Looking forward to watching this Bud!!
What are you planning on for suspension? Strutted/ridged or sprung? Give us some more details.
You gonna build a tank? Could always build one similar to what I did on the 1100. Super easy out of sheetmetal.
Keep the pics coming...
Ok forums are dead. Gonna revive this thread. So after thought im not using the 250 frame and will be using the good old zilla frame. I got the jig made for building the front end and the swingarm jig isnt far behind. After thought and measuring the 250 frame is lighter than a 500 but also way shorter and I think ill be further ahead to use the zilla frame. If I do the 250 ill have to add 6 inches just to get to the length of a stock zilla frame. Pics to follow.
After some more thought I reworked the jig a little in the way the carrier clamps in. Here is where im at tonight. May come to a slight halt till after the last race of the year sunday then i can take my swinger off for some measurements. Gotta love working 3rd shift... :-)
ive seen rear carrier jig similar to that before. kelly baldwin has something like that
Looking good. I like these custom build threads!!!
Progress being made. Motor tore down and shipped to hpr for some love. Hope to have it together early enough to go on the dyno for some pulls. Chassis progress pics soon should def be one of a kind...
I like the swing arm Jig, I need to build one myself would make things go much faster.
Any suggestions carl? Im open too them. I based this jig off a pic i saw that stellar machine had but there's was made from aluminum. I kept universal as long as its a 40mm carrier. The front pivot mounts are removable just incase i get tired of zilla's im gonna start on my arched ladderbar swinger. Any recommendations on tuning size? I kicked around 3/4 want it light but strong. I have a bunch of 3/4 .058 wall. Might go with 3/4 .075 wall for the main tubes and the .058 wall for bracing.
Im also thinking of torque strutz on the side of the swinger to handle the torque since im going from a +3 to a +6 this bike will be one of a kind for sure.
That sounds good what are you gonna use to arc the tubing a roller. That will be the hardest part getting them the same. Be sure to leave the tubing at leas;t a foot long on each end or you'll end up with flat section. Can use the ends for bracing.
Yea prob use the trusty tubing roller. Nice thing bout jig is it wont matter if they are off a smidge it will be straight either way once i take it outta the jig.
Yes that is the a benefit of a jig and makes fitting the parts faster
Progress pics this afternoon... this bike is certainly going to be one of a kind thats for sure.
Any feedback thought or idea are appreciated. I know this isnt what the title says but in order to start on my new set-up i gotta build this stuff... 
