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.

Welded this spot where the swing arm bolt runs through. It was only tac welded from factory

Lower frame section in front of the motor mounts

Here is how they look after powder

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.

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!!

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.

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.

It's powdercoat not paint. I have plenty of spark.

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.

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.

Well the bike is finally all together. Not done by any means but it's together.

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.