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DT125R Forum -> Projects -> My New Project - 2001 DT Strip and Build!!!
Post Info TOPIC: My New Project - 2001 DT Strip and Build!!!
coastie123


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My New Project - 2001 DT Strip and Build!!!
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Right Guys and Girls, Heres my new project thread!!!

 

I spent a few cold nights in the garage doing my other bike and thoroughly enjoyed it!! heres the link http://dt125r.activeboard.com/t47459482/1999-dtr-project-hopefully-3-months/

 

My new project is a 2001 DTR it's currently black with a small amount of Monster stickers on it.. Heres some pics as it stands at the moment...

It has a Full DEP System on it at the moment but the expanny has a fair amount of Rust and a few dents and I've also found a small pin prick hole.. It also looks like it's had a few tack welds at somepoint (Last Pic)

 

So there we have it..

 

so far i know it needs..

  • front inner tube
  • CDI
  • front Expanny
  • Rewire/New Loom
  • Front Wheel Bearings
  • new Renthals
  • New Front Brake Master
  • New Brake Lines, It's got Braided lines but not the best..
  • Front & Rear Pads
  • Chain and Sprocket
  • New levers..

so a nice little project again!!! I will be starting the horrible task of stripping it down over the next few weekends

The frame is quite tidy so i may/may not powdercoat it..

the Dep will be probably stubbied and polished (Hint NEV!!!) and i've also got a few paint schemes in mind - Yes you read right - PAINT not Decals!!

Hope you like the pics so far!!



-- Edited by coastie123 on Saturday 6th of October 2012 10:08:43 PM

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NEV


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Oh aye deffo but I'd rather go with with gas(oxy aceteline) than stick, but if you only have stick, and your plant goes down to around 25 amps, you can break the arc and lose about another 4-5 amps roughly, but if its tissue paper you need to build it up. I have gas welding gear but need to get a full size oxygen bottle swapped, hopefully on Monday I'll find out if my mate can work it in with his stuff and get it changed that way. Then I'll have a crack at welding Coasties exhaust up. 
Built this the other week using stick, and even with brand new steel drum, it blew through now and again, if I got too adventurous whilst doing a run,



Uploaded with ImageShack.us



-- Edited by NEV on Sunday 7th of October 2012 12:59:13 AM

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NEV


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Seen that bike before am sure of it, stripping down should take care of one weekend I reckon. As for the exhaust I see what ya mean now, I'd be hard pushed to weld that up with gas never mind stick, needs "mending with a new un" mate, as me dear old gran used to say.

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coastie123


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The main rust is on the expanny, the frame is quite tidy which I was shocked at.. I've know the last 3 owners of the bike and quite surprised its in quite good nik!

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NEV


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I think you mean 'blob' method Wozz, a 'stitch' weld is a tad longer than a tack weld.

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NEV


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A tack weld is just to hold two parent metals together , regardless of thickness. I only know this as I'm ASME9 coded on pipe, (low hydrogen), and Lloyds 4871/2 coded on plate.
I think you mean blob weld mate



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NEV


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went in on friday got half a bagfull cost me £23, mainly m6, hex n allen bolts, all lengths. Next time yer up Trago, get a couple of cans of carb cleaner, that brings all the wires up nice n clean.



-- Edited by NEV on Sunday 7th of October 2012 12:46:38 PM

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NEV


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Shrink wrap aye, I've had from them in the past, still Yambits for connectors, the block connectors I'd wait till you see how many are missing, as usually they'll clean up well if theyre there, and if missing can get away with two bullets instead. Oh aye, plenty of small cable ties, both black and white so as to make codes for the wiring.



-- Edited by NEV on Sunday 7th of October 2012 01:05:26 PM

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FunkeyMunkeyDavid


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looks like it needs some love lol beware of those monster stickers,they attract chavs like no-ones business biggrin 



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coastie123


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ha!! I know.. There coming off now anyway!!!

Just a little update... spent a half hour in the garage earlier and managed to get the panels and seat off..









took the headlight cowl etc off and the loom as i expected has been chopped, bits added etc so a full loom strip will be in order to see if it's worth fixing or buying another!!





I love all these jobs!!

Looks like i've found a few for NEV to do along the way aswell!!!!

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Nathlaad


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Nice little project there mate! bet you cant wait to get your hands dirty!

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NEV


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No problemo, get in plenty of 3/5/12mm shrink tube, and those yellow and blue plastic covered metal crimps will sort that lot out. 2x loom wrap, and Yambits for silicon covered connections.
codes for Yambits connections
electrical connectors
male bullet 3.9mm x10 ELP007 82p
male bullet 3.9mm silicon outer sleeve x10 ELP008 51p
female bullet 3.9mm x10 ELP009 82p
female bullet 3.9mm silicon outer sleeve x10 ELP010 82p
female bullet 3.9mm double socket x5 ELP011 92p
female bullet 3.9mm double socket silicon outer sleeve x5 ELP012 71p
female spade 6.3mm x10 ELP013 £1.25
female spade 6.3mm silicon outer sleeve x10 ELP014 £1.25


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coastie123


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there already dirty with the amount of grease and mud over it!!

Can't spend alot of time in the garage today as its my eldests birthday, managed to get him a scooter (he's only 7 so push along) but a good excuse to go in the garage!!!

i've got a quite a few connectors already nev but will defo order some more... do you think you could get me a few handfulls of bolts at somepoint??

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coastie123


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NEV wrote:

No problemo, get in plenty of 3/5/12mm shrink tube, and those yellow and blue plastic covered metal crimps will sort that lot out. 2x loom wrap, and Yambits for silicon covered connections.
codes for Yambits connections
electrical connectors
male bullet 3.9mm x10 ELP007 82p
male bullet 3.9mm silicon outer sleeve x10 ELP008 51p
female bullet 3.9mm x10 ELP009 82p
female bullet 3.9mm silicon outer sleeve x10 ELP010 82p
female bullet 3.9mm double socket x5 ELP011 92p
female bullet 3.9mm double socket silicon outer sleeve x5 ELP012 71p
female spade 6.3mm x10 ELP013 £1.25
female spade 6.3mm silicon outer sleeve x10 ELP014 £1.25

 Do you rekon 6m of each size will do!!!!



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coastie123


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i've got 3 cans, but will be popping to trago on saturday so will be getting some more bits then..

feel free to grab the bolts, let me know what the cost is and will sort it all out, shame there not open saturdays!!

this is the guy i use on Ebay http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=160809668245&var=460074510294

rather than use yambits, what about these http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=360453801259

how many of these and what sizes will i need http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=170575507225



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NEV


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Probably get away with 3m, oh that external stuff too, 15mm or 13mm cable tidy stuff @2m

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coastie123


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loom wrap - http://www.ebay.co.uk/itm/Wiring-Loom-Harness-Adhesive-Cloth-Fabric-tape-19mm-25m-/180637405593



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coastie123


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right, just another small update..

Postman arrived today with a few little packets!!



so went in the garage earlier to start stripping down the loom... it's mud all over the frame, not Rust!!




and then came across this little thing, wasn't plugged in to anything.. anyone know what loom this is from?? it wasnt on my last DT which is from the same year 1999-2003



so getting there with this project, oh and i've got a SM setup on the way to me!!!!



-- Edited by coastie123 on Wednesday 10th of October 2012 08:53:56 PM



-- Edited by coastie123 on Wednesday 10th of October 2012 08:54:53 PM

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WoZz


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Nev,
I looked at a dep exhaust the other day.
And i can see exactly what you mean now, there not very thick lol.
(Don't want to think how thin it is with the rust)

BBQ looks nice by the way (I assume that's what it is)

coastie123,
Looks like you're knee deep into it now lol.

And i don't think my 98-03 loom has that white connector either,
I'll have a look tomorrow and report back if it has one.



-- Edited by WoZz on Wednesday 10th of October 2012 09:29:20 PM

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NEV


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Am sure Norfe had that connector block on his loom Coastie, in old Electrics thread I think it is, ta Wozz, aye its a Smoker/BBQ, bottom drums the firebox/smoker.

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MDK


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looks like nice dirty fun....I always start with a good jet/power wash wilst the bikes in one peice and everythings still coverd or sealed ....

pressure steamers are great for that job.....





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good clean up of a old batterd  dtr  95

 
DT200R MACCA


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that little thing thats not plugged in is for the speedo light and the speedo restricter



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Calum122


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I love seeing people restoring DT's.

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WoZz


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DT200R MACCA wrote:

that little thing thats not plugged in is for the speedo light and the speedo restricter

I thought the speedo light was a 2 wire black and blue? Or at least it is on my clocks.

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NathanH


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Cant wait to see your new wheels! ;)

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coastie123


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right guys, another little update!!

I've been pacing up and down at work all morning waiting for the ****tyLink van to arrive!!!

he always turns up between 9am-9.30 but he didnt turn up untill 1030is - Bar steward!!!

anyway, enough of the chatting and heres a couple of pics of my delivery!

Sorry for the light, but it's dark in my garage, ill take some better ones at the weekend!!





Whoop de Whoop!! !8" front TDR wheel and Rear 17", both powdercoated black with Stainless spokes, brembo twin pot caliper and yamaha nissin master cylinder, both discs, spindles and speedo drive etc

Over the moon with them!!

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FunkeyMunkeyDavid


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V nice!



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NEV


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You need those Pirelli Speed Demons I have here, on those mate, bring them with ya Saturday, ATS will bang em on for a fiver.

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coastie123


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Right another little update...

Managed to get all the bolts etc except for the swingarm bolt!!!

It's bloody seized!!

I've managed to free it up a bit and it now spins with a ratchet but won't bloody budge out the frame/swingarm..

Will be applying a lump hammer and a few swear words to it tomorrow..

I thought u would have problems with all the bolts but a few little burst of "Liquid Wrench" an hey presto they move with no problems - I highly recommend it!!!

Will update again by Saturday with my result on the bolt!!!

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coastie123


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Well what an eventful day I've had with this bloody swingarm spindle...

It resulted in being a fireman & trip to a&e rather than down to Nev's house!!!

I decided to heat up using a blowtorch.... That was fine but I had forgotten about the puddle of wd40/liquid wrench, I had also just poured a nice cup of coffee and had to use that to put the flames out!!!

Anyway, after all that and made myself another cuppa, I sprayed tonnes of liquid wrench and Wurths rost off on the spindle... Left it a couple of minutes and then started bashing away at the spindle after a couple of minutes of bashing away, something splashed in my eye... Not really a good combination so I dashed upstairs to wash it but still had trouble seeing/opening my eye!!

After 4.5-5 hours in a&e, I had my eye flushed some iodine stuff put in.. It now seems that a small bit of spindle ended up in it aswell!!!

Sorry nev!!!!

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