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Author Topic: 1992 LT250 frame gusset.  (Read 7947 times)

Offline 92lt250wannabe

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1992 LT250 frame gusset.
« on: February 11, 2015, 05:59:22 pm »
I am restoring/upgrading my 1992 250, the frame it came with was bent, and was very noticeable on trail riding. So I picked up a good frame and did a little research about gusseting it. I didn't have a lot of success finding info on the places to gusset just a few genaral weak spots. So I will post up where I put gussets on my frame. I will post a few before and after powder pics also.

I hope this will help out any of those in question of gusseting an lt frame. It should be about the same for all years and the zilla as well.

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Offline 92lt250wannabe

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Re: 1992 LT250 frame gusset.
« Reply #1 on: February 11, 2015, 06:00:22 pm »
Rear triangle upper and lower

Offline 92lt250wannabe

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Re: 1992 LT250 frame gusset.
« Reply #2 on: February 11, 2015, 06:01:32 pm »
Welded this spot where the swing arm bolt runs through. It was only tac welded from factory

Offline 92lt250wannabe

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Re: 1992 LT250 frame gusset.
« Reply #3 on: February 11, 2015, 06:03:30 pm »
Gussets in lower motor mount area to prevent frame twisting

Offline 92lt250wannabe

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Re: 1992 LT250 frame gusset.
« Reply #4 on: February 11, 2015, 06:04:57 pm »
Lower frame section in front of the motor mounts

Offline 92lt250wannabe

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Re: 1992 LT250 frame gusset.
« Reply #5 on: February 11, 2015, 06:05:53 pm »
Lower section at very front of frame

Offline 92lt250wannabe

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Re: 1992 LT250 frame gusset.
« Reply #6 on: February 11, 2015, 06:07:23 pm »
Here is how they look after powder

Offline 92lt250wannabe

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Re: 1992 LT250 frame gusset.
« Reply #7 on: February 11, 2015, 06:09:17 pm »

Offline 92lt250wannabe

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Re: 1992 LT250 frame gusset.
« Reply #8 on: February 11, 2015, 06:13:57 pm »
I hope this helps people in question. I did gusset the rear triangle on all 3 corners. I only pictured one or 2 that I welded in. Also the front end above the upper front a arm mount I gusseted that corner as well. I think I put a total of about 18 or more gussets all together. It didn't interfere with anything mechanical whatsoever.

I cut little template pieces out of cereal box cardboard first, it made the trimming and fitting very easy. Than I traced them out on my 1/8" steel plate and cut them out. Smoothed the sharp edges on the grinder and welded them up.

I also numbered them as I went along and numbered the frame. Lots of pieces were so close but slightly different.

Offline GrkGuy

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Re: 1992 LT250 frame gusset.
« Reply #9 on: February 12, 2015, 11:53:51 am »
Did you have any bolts or hardware on frame when you welded it, I had frame welded and the gussets pulled frame and I had hard time getting motor bolts to line up,
life's journey is not to arrive at the grave safely in a well preserved body, but rather to skid in sidays totally worn out shouting "HOLY SH*T...WHAT A RIDE!"

Offline Patman13mia

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Re: 1992 LT250 frame gusset.
« Reply #10 on: February 12, 2015, 01:25:14 pm »
if thats the case then somebody was welding in one area to long. can tac a 1-2 inch bead and then move to another gusset.. then bounce around when one gets hot back to the one that is cold again.. i have used this method on 2 frames now and has worked great..

zach- those gussets look good dude!! nice straight cuts and great welds. your bike is looking sick dude!!

Offline GrkGuy

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Re: 1992 LT250 frame gusset.
« Reply #11 on: February 12, 2015, 05:44:31 pm »
Yeah maybe that was the case I had a friend do it, but he is a good welder.
But I got it to work I had to grind one down more for the lord pipe to fit but other than that
The bike is ready to take a beating.
life's journey is not to arrive at the grave safely in a well preserved body, but rather to skid in sidays totally worn out shouting "HOLY SH*T...WHAT A RIDE!"

Offline 92lt250wannabe

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Re: 1992 LT250 frame gusset.
« Reply #12 on: February 12, 2015, 08:48:58 pm »
I didn't have any bolts in the frame no. We did exactly what pat said. We tacked a few in and made sure the fit was perfect. Than moved from front to rear, and bounced around like that until they were done. Everything bolted up perfectly without any issues. Let me tell you the frame I got orriginally that was bent Was a **** to get the motor bolts to line up for sure. The  motor mount that runs to the head wouldn't even fit. The only thing I have yet to put on the bike is the swingarm. But the bolt is through te back of the motor and it fits like a glove.

Offline 92lt250wannabe

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Re: 1992 LT250 frame gusset.
« Reply #13 on: February 12, 2015, 08:53:22 pm »
Thanks pat for the complement on the bike. It's hangin out in the basement right now keeping warm. It's about -7 degrees out at the moment..

Here it is with some of the parts back on. It's much further along than this right now but it's jusst a pic showing that everything bolted up without any problems.



Offline QuadRacerZ

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Re: 1992 LT250 frame gusset.
« Reply #14 on: February 16, 2015, 09:19:47 pm »
Looks really nice man. What kind of exhaust is that? A little hard for me to tell... I was overviewing my bike again today while I was working on it and the previous owner seems to have already gusseted some of the spots that you have already.

As always... Keep me updated on anything you do to your bike or what info you may get on good deals.

Offline B_Fuss

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Re: 1992 LT250 frame gusset.
« Reply #15 on: February 16, 2015, 09:28:23 pm »
I noticed paint or powder coat.  On the engine mounting holes.  I hope you cleaned it off before assembly.  If not you may have problems with grounding/electrical.

Offline 92lt250wannabe

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Re: 1992 LT250 frame gusset.
« Reply #16 on: February 17, 2015, 03:48:41 am »
It's powdercoat not paint. I have plenty of spark.

Offline QuadRacerZ

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Re: 1992 LT250 frame gusset.
« Reply #17 on: February 19, 2015, 12:55:18 am »
Havent heard from you in a couple days bro... Hows the bike coming? Please let me know if you have any leads on front A Arms... Even if they are only +1... I really dont want to have to be stuck with just the camber mod.

Offline 92lt250wannabe

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Re: 1992 LT250 frame gusset.
« Reply #18 on: February 19, 2015, 09:18:30 am »
What's up dude. No more progress on bike. It's so cold where I live its hibernating in my basement until April or May haha. I will b gettin my swingarm back tomorrow. U have a post on by heminutt saying that he has some a arms for sale. I will get some more pictures up soon along with a build thread.

Offline QuadRacerZ

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Re: 1992 LT250 frame gusset.
« Reply #19 on: February 20, 2015, 10:16:43 am »
Sorry for your weather issues. Put a heater in there! Haha... Springs is starting earler where I live and its been mid 60's most of the week. Which means Im hustling to get most of the stuff I need in order to make the most out of my riding year.

Offline 92lt250wannabe

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Re: 1992 LT250 frame gusset.
« Reply #20 on: February 20, 2015, 06:36:15 pm »
Well the quad is in the basement. so it's 65 down there but outside is pretty cold. We have about 30" of ice on the lakes.

Offline QuadRacerZ

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Re: 1992 LT250 frame gusset.
« Reply #21 on: February 21, 2015, 09:38:31 am »
65 degrees in the basement? With all due respect... thats more reason to work on it lol

Offline 92lt250wannabe

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Re: 1992 LT250 frame gusset.
« Reply #22 on: February 21, 2015, 09:02:12 pm »
Well the bike is finally all together. Not done by any means but it's together.


Offline QuadRacerZ

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Re: 1992 LT250 frame gusset.
« Reply #23 on: February 22, 2015, 09:09:26 am »
Damn... Looks good, What kind of shocks are those? And I wish I still had the heel guards for mine.

Offline 92lt250wannabe

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Re: 1992 LT250 frame gusset.
« Reply #24 on: February 22, 2015, 11:04:47 am »
They r works. I rebuilt them myself (super easy) and had the springs powdercoated. I kept the top spring white but wanted them to look kind of stock like so had the lower spring done to match factory yellow.

 

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