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DT125R Forum -> Projects -> Project 92 DTR AKA Big Pile of Bits
Post Info TOPIC: Project 92 DTR AKA Big Pile of Bits
Slinky


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Project 92 DTR AKA Big Pile of Bits
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Totally new to bikes, my background is classic Minis.  I have an ongoing money pit that is a 92 mini that is gonna run a Vauxhall 1.6 16v engine using Yamaha R1 carbs.  Had it for over 8 years and still not finished it.

 

 

Anyhow, enough about that.  I never ridden a bike before let alone owned one but have wanted one forever.  After looking about a bit and a drunken bid on Ebay I got myself a 92 DTR, or should I say the remains of one.  The plan is to get it road worthy, get my bike license and commute to work on it.

 

 

 

As you can see I have amassed a shed load (literally) of bits.  I am going to attempt to fit the USDs I got, think they are a 2001 YZ250 set.  The engine is pretty much all there and will be over bored a wee bit and completely rebuilt.  I have got a full set of SM plastics but will need to modify the frame for them to fit and mod the seat a bit.

 

The plan is to get a YZ125/250 front wheel, standard DTR back wheel, full DEP exhaust, aftermarket digital speedo and see how I get on from there.

 

Total novice so any hints and tips would be appreciated.

 

In the process of stripping the frame and parts:-

 

 

  

Mocked up the SM panels, seat and tank to see how they would fit and they will need some modding

 



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NEV


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Very nice, look forward to seeing it all come together mate.

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SUPERSTEVE


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Love mini's dude!! Especially bike engined 1's lol my gf won't let me get 1. She calls me mr bean wannabe lol.

A dtr with dtre panels, most like the old school panels but I'm not fussed, I loved my RE even though I didn't get to ride it :)

Keep us updated, we all like the pictures.

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ToySoldier


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nice one man i was watching that on ebay =]

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Slinky


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ToySoldier wrote:

nice one man i was watching that on ebay =]

 

Yeah decided just to dig in and get it built. Got loads of spares tho so they'll be back on eBay eventually.

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NEV


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I do like those tail ends, I bought black smoke lens spray for one, then found out how much they were going for on ebay

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Nathlaad


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Cant wait to see some progress on this mate, sound like you know your stuff so its gunna be good to see the end product!


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DT-R_bradders


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hey man that mini is looking sweet! good little project u got goin on there dude, btw do you know wat year the yz250 was for them forks? coz the wheels differ quite a bit, i wasnt sure on the year of mine wen i got them and had nightmare trying to find the right wheel for them cos the hubs are different on alot of them and the disc dont line up properly or disc sizes are slightly different and also the axle sizes are different, think i brought like 2 or 3 different wheels before one of them fitted correctly lol i now know mine are from a 91 yz125

 

keep up the good work dude!



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FREZOI


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Nice mini mate, ive got one aswell but its needing alot of work still looking pretty nasty but ive started buying bits for it and sourcing a cheap second hand cage for itevileye way to put a removable front on it and was looking at a vauxhall 2 litre redtop for it.

anyway the bits all look decent nic for the bike, getting the frame powder coated? anyway should look good when its done cant wait to see the results!

 

Got some photos of my mini and my bike in my album, btw what body kit you using on yours looks pretty smart seen an orange one with a kit similar to that

http://imageshack.us/g/696/sam5031.jpg/



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Slinky


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DT-R_bradders wrote:

hey man that mini is looking sweet! good little project u got goin on there dude, btw do you know wat year the yz250 was for them forks? coz the wheels differ quite a bit, i wasnt sure on the year of mine wen i got them and had nightmare trying to find the right wheel for them cos the hubs are different on alot of them and the disc dont line up properly or disc sizes are slightly different and also the axle sizes are different, think i brought like 2 or 3 different wheels before one of them fitted correctly lol i now know mine are from a 91 yz125

 

keep up the good work dude!

 

Pretty sure mine are off a 2001 YZ250.  Bit of a nightmare trying to find parts for it.  Got the front brake and two sets of yolks for it.  Need to find a machining shop to do the transformation.



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Slinky


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FREZOI wrote:

Nice mini mate, ive got one aswell but its needing alot of work still looking pretty nasty but ive started buying bits for it and sourcing a cheap second hand cage for itevileye way to put a removable front on it and was looking at a vauxhall 2 litre redtop for it.

anyway the bits all look decent nic for the bike, getting the frame powder coated? anyway should look good when its done cant wait to see the results!

 

Got some photos of my mini and my bike in my album, btw what body kit you using on yours looks pretty smart seen an orange one with a kit similar to that

http://imageshack.us/g/696/sam5031.jpg/

 I'm sticking with the 1.6 16v as it's lighter and fits in a standard front end.  Got the Allspeed subframe kit so slots right in.  Bodykit took months to fit but was worth it, I think it really suits the mini.  Going for a light weight street racer finish - every part possible is fibreglass.

 

Was going to get the frame powdercoated but didn't fancy forking out so much money so got a load of rattle cans of etch primer, primer and tough gloss black so will hopefully look as good, if not as long wearing.  I've got a wedding, a mini and a mortgage to pay for so doing everything on a budget....



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Slinky


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Wee bit of an update, stripped the frame back to bare metal.  Looks actually quite good all shiny, was tempted to polish it up and then just laquer it but too much work involved.

First layer of etch primer on, will do a few coats then a few coats of primer before the gloss black.

Also started spraying a few parts, colour scheme is black and gold, or Ford Solar Gold to be precise (had some cans left over from a previous project).

Got some stickers to match through the other day.  Next job on the list is to finish the paint work then once my replacement crank cases arrive i'll tackle the engine rebuild. Fun stuff...



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Slinky


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Bit of an update, have now changed my plans for this bike and sold all the sm bits, gonna go the traditional route with DTR panels. Got myself the seat and went about stripping it, ready fro prepping for the hpires rear panel Had a bit of bother getting the rear shock dis-assembled. The spring compressors I had were designed for car shocks so a little chop here and there.. .... and I managed to get the rear shock in bits ready for painting. Got a delivery from Portugal and mocked up some of the new panels along with the seat and tank. Doing what I can, when I can, started priming and painting the various plastic parts on the bike.... Got another part through the post... Rear shock being primed for paint.... Managed to pick up a 2001 YZ250 wheel and disc. I'm gonna break this down and use the hub and disc and build it up onto a supermoto style rim. So this is going to be going spare.... Also managed to get another set of USDs from the same guy, between the two sets I have and the seal kit I got i'll put together the best set of forks I can. After trying to spray the frame using rattle cans and realising how rubbish the finish was I stripped the frame again and will be taking it to get powdercoated hopefully this week. I've been stripping the various brackets etc as well ready for powdercoating. Mock fitted the rear fender and don't know where i'm going wrong but it doesn't seem to marry up - should there be this gap? That's all for now folks, hopefully next update will be powdercoated frame and rebuilt forks. I'm in talks with Bradders to do my yolks oh yeah and i've changed the colour scheme as the bike was originally white and seen some cool bikes on here I thought i'd go with white. The orange was inspired by that mental Caterham James May had on top gear recently, so white black and orange it is now.

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ToySoldier


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dude dude once u build up a set of forks will you sell me the rest of it lol i have a set of usd's i wanna fit but there a bit ruff haha

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Seiki


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The gap on the back fender is normal. I used a metal pipe then a few washers . It's stayed sturdy for years, it also causes the fender to have a nice bend.

Great project and great start.



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Slinky


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ToySoldier wrote:

dude dude once u build up a set of forks will you sell me the rest of it lol i have a set of usd's i wanna fit but there a bit ruff haha

 No bother, should have a spare (yet crap) set of yolks too and the rim and spokes if you're interested.  Have got time off work just now so will hopefully get things done asap.



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MDK


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yeah looking good

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DTR125CO-1.jpg


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good clean up of a old batterd  dtr  95

 
ToySoldier


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sounds awesome to me mate =] btw going to look good when its all done =]

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Seanyftw


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goddamnit wish i had the time and money to do all this myself :(

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Slinky


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Wee bit of an update.  Firstly got together the frame and bits and took them on a wee trip to Pentland Powder Coating, will be picking them up next week so hopefully they'll be looking good...

 

 

Next, I went about dismantling the YZ250 front wheel and disc.  Took freaking ages, but got there in the end.  Took a wee bit to clean up then primed and on with the paint.  I'm using Hycote double acrylic paint and it seems to be noticably better than the usual rattle cans - very thick and clingy, but we'll see in the long term if it lasts.  It's VW Brilliant Orange if there are any paint spotters out there.

 

 

 

 

 

 

So i'm waiting on the frame and bits coming back and in the meantime i'm going to tackle the forks...

 

 

Will hopefully have another update next week.



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eG x LoGiKzZ


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im liking the orange hub, the finish looks really good

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dan


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I always love to see bikes inside homes.

Nice job so far, expect your wallet to take a beatin.



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Slinky


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Picked up the bike and bits from the powder coaters and it was like Chirstmas - awesome finish and totally worth the money.

 

 

 

 

 

I was so impressed with the finish i'm going to get the hubs and other orange bits done properly there.  Mocked up some bits on the frame and put together what I could.

 

 

 

Got the transfers through for the frame and bits and wanted to see how they'd look so put the ones onto the swing arm.

 

 

Never managed to get the forks in bits, looked at youtube videos of it but couldn't get the bottom big allen key bolt properly undone, will try again later.



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MDK


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no fair you get to rebuild in the house it seems ?

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good clean up of a old batterd  dtr  95

 
eG x LoGiKzZ


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dented petrol tank?

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eG x LoGiKzZ


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also, how much did it cost you to get all your parts powdercoated, if you don't mind saying?

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DT-R_bradders


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looking spot on slinky dude shame about the small dents in the tank tho, i cant w8 to rebuild mine again, im gonna mod the head tube on the frame by extending it next time tho as im really not happy with how my usd yokes are fitted atm, did you try a mock up fit of ur usd's before u powder coated the frame??

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Slinky


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Yup, little disappointed with the tank, couldn't see the dents before the powder coating, but I can live with them and may try to cover them with decals. Not trial fitted the usds yet, still working on them. Cost for powder coating everything in the picture and welding up a crack in the frame was £160 which I thought was quite reasonable.

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eG x LoGiKzZ


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seriously? i was expecting it to be alot more, good to know as i plan to get my bike done similar to this

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NathanH


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looks awesome! What front mud guard and headlight are you going for?

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