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Discussion Starter · #1 ·
After parting a 5 machines in 2 months I'm left with stuff no one wants. I can barely give it away, plus now that we are in the winter months (dec -1 april 13th) stuff does not like to sell. Some models I sell every part, others only a few parts.

I took some of the stuff to work and built new stuff for that stuff.

So what do we have here you ask?

trx300ex frame with egged out swinger holes (lazer cut plates fix that)
trx450r front shocks (blown needing rebuild and revalve)
trx400ex oem a arms I had got in a trade to get rid of more stuff (I cut the ends off to convert over to remobable ball joints)

A tape measure, a Level and an angle finder go along way, however I do also over see a manchine shop.

Those stupid 300/400 shock extender brackets are less then perfect plus you dont need to keep the 400ex angles on the 300ex. The reason they were made is bacause nation MX rules only allow bolt on parts. Back in the day you build your own frame or cut up a stock on, never bolted things on!

So I built a trx450r shock tower from scrap metal. I didn't like it. So I build a 300ex shock tower out of it. I then set my a-arm height and where things fell they got tac'd in place by me. Later didn't like my 1st bracket conversion. I reworked it. Next were gussets. I later didn't like my round ones so I redid them with 1x1.083 wall tubing so it matched factory a bit more.

Next I will extend the frame. I might prob should of extended it 1st but I had planed on building a new shock tower in the 1st place. I planed for running my works front shocks on +1 forward a-arms.

Once I got nice OEM arms in a trade to get rid of more stuff plus cash my direction changed. I even had old PRM a-arm skid plates laying around that didn't sell.

I have a bad shape atc350x swingarm. I have a good shape 300ex swingarm. Might just mix them together. rear shock can be anything honestly, worst case a rebuild revalved and resprung 350x rear shock.
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I am no stranger to putting things in places they didnt belong. It's hard not, just after awhile you figure out anything can be done with a welder and a lathe or drill press.

Stay tuned girl scouts
 

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Discussion Starter · #2 ·
Just pulled this junk down from the loft. Nothing like loosing your job for no reason so I put this project away until a later date which is now again.

Currently building + 1.5" wide +1 forward a arms. I chose +1.5 wider since that matched my oem 400ex a arms I had.

Many things were powder coated black already or redone.

Last night I removed the frame to airbox tubes. They take up too much room. The airbox needs a plug in which I made from some uhmw plastic I had.

Until next time.
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Discussion Starter · #3 ·
I bought 3 more 300ex's for a few parts and parted them.

I will build my daughter a stock platform with old works performance shocks shock up front and upgrade her OEM swingarm to work with a warrior 350 rebuildable rear shock I have. I took her OEM 300ex a arms and cut off the ball joints to weld in 16mm T hat threaded sleaves so I can run replaceable ball joints on hers. I didnt think a an 8yo really needed a wider machine right now. I still have my not stock 300ex frame that will be extended +1 forward and longer swinger build. Try to add some photos later.
 

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Discussion Starter · #4 ·
Did a bit more. Not sure which one I will build 1st. Both frames are copies besides one runs 300ex shocks and one runs 450r front shocks. Ending Up sell my atc350x project but kept a good bit to use on the 300ex's

My daughters 300ex will get a warrior 350 rear shock which is a really nice upgrade from 300ex. Its pretty soft in stock valving. I wanted to lower the back some so did not want to use a 660r shock, plus i already had a warrior shock from parting one out. OEM 300ex a arms cut to and welded in sleeve to 16mm ball joints. She did not need crazy wide arms to move up to a larger machine yet. Total investment....100% free so far yet.

I will modifit my 350x swingarm again to run on either 300ex with the warrior shock.

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Discussion Starter · #6 ·
Not done yet. I ending up selling my extra 300ex frame with the 450r shock mount and the shocks. It was a mega payday. Ok so I parted 2 or 3 more 300exs.

Now I did even more mods to the kids future 300ex. Warrior shock is fully in place with delrin upper shock bushings and new 12mm Sleve. More frame mods to hardmount the bottle up front where we use to mount works bottles. I went to local hydrualic store after work and had a new line made. Figured out my new rear shock mount for 350x swinger to mount warrior shock. I am lowering the rear 1inch over factory 300exs. 2009 300x motor has been built, fly cut cylinder, pro-x piston with oem cam. All new head build with 5 angle valve grind... these things can be build like tractors...does not need to scream they don't last in that state or make it great for a kid. I have 2 motors left over in parts.

Prob just buy Elka fronts however I did redo a set of oem front shocks for kid as that might be good enough. I relocated rear trx450r rear brake resivour too inside frame away from exhaust.

Finishing up my shark fin style skid plate for sprocket guard and rotor fin.

Need to build my 300ex fmf header to oem 400ex muffler yet.. Don't need the noise and 300exs exhausts are gone. I keep buying parts bikes than selling parts off so I get what I need.

Stay tuned. When your in no rush cool things happen.
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Discussion Starter · #7 ·
Kb5 industrues did my head and cylinder for me. He services a national race team. Very great guy to deal with....all my heads and cylinders go to him.

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Top end rebuild with fly cut cylinder and reached head. 5 angle valve grind 100% new all oem valve parts and guides. Prox piston to keep weight off crank. 75mm bore. Cam goes in next. No rush needed a few more oem gaskets.

Next I'll relocate battery up front i think to gain more free space in rear. Engineering mostly finished.
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Discussion Starter · #8 ·
Finished laser cutting my shark fin designed skid plate. These are custom made on each machine I build. Normal skid plates are junk and fold. I need to Weld it and than figure out my gussests. Swingarms get new welded tabs on the bottoms for bolts. I've build these for multiple machines over the years running custom Swingarms.

Tomorrow my new shock mount should be welded up. Everything check out tonight before weldings. Lowered seat height 1/2" over-all before shocks sag. Should be 1inch lower over all once shocks built & revolved.

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Discussion Starter · #10 ·
Needed to cut the electronics out of the way of the shock line. Was too close to work properly. I will plate that side of the frame shut like other side and relocate the 2 electronics else-ware. Hoping I was put everything up front under the nose / hood. Cam was put in time / cam adjuster and intake manifold on. Everything got new OEM gaskets or O-rings. Now to do something else for a bit like buy more 300's and part them for profit. I have nothing into this build and currently still $1100 to the good.
 

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Discussion Starter · #11 ·
Weekend homework. Gusset for warrior shock mounts on 350x swingarm. Laser this guy out weld in. Might need 2 small ones yet but I'll check after it's in.

I finished putting the valve cover on last night
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Discussion Starter · #13 ·
Had been after a guy to make me a set of real foo pegs. Normally I buy used roll deisgn pegs cut up and fab for my machines but he has a really good design just a tad skinner than I prefer. Stock is 1inch if that. These are 1.75inch wide. My roll pegs are 2.50inch wide.

However one thing I had less to make. He sent me the 1st prototype to test. I had to provide some feedback and have holes moves and opened up. He will be selling them on ebay along side his other vintage atv pegs. Wicked metals Inc. Is his ebay and facebook name.

Next I was onto wireharnesses. Not sure why they need to end up in spaghetti or all cut up. A $25 manual gives you the full schematic so no thinking is involved. Remove what's needed or let go. Kids and wanna be racers...always.

4 harnessess and kill switches = 1 good set. Not all hacked up or deleted. I'm over those days...3 wires less won't make the fastest of the fasted faster.

I had to canabilze parts of various kill switches to make a nice 2007-09 style. I am using 1993-2006 full wireharness since the 07-09 only incorporated the reverse inhibitor cdi into the main cdi....than gave everything different plugs. Was not gonna buy $500 of parts just for that reasons. I am running 2007 -2009 motor. Insides are different in gear box less parts vs 1993-2006. Way simpler 25 less moving parts.

No rush here. Just more tricks to come.
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Ok next time girl scouts
 

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Discussion Starter · #14 ·
New battery box made, relocated up front on frame nose. Oem a arms all finished. I have threaded inserts in them for ball joints and skid plates
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Discussion Starter · #16 ·
400ex muffler found its new home. Welded two threaded bosses on. Have to turn a spacer adapter to Weld to my fmf header. I wanted to keep it quiet. A turndown stinger will be added next too. Home stretch
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Discussion Starter · #17 ·
Swinger done off to powder coat sliver like the a arms. Final mods on frame for new location of solenoid holder. Took my oem fender stay cut it up welded it so supplied maier brackets, powder coated it and added rubber washers to mount...floppy fenders gone. Stay tuned.

I guess no one on here builds atv anymore unless they bolt together lol.

Total cost still free.
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Discussion Starter · #19 ·
Almost buttoned up the rear end. Cat decided to chew my new rear calipers seals when I walked away for 10 mins. Mounted up like it was designed to. Now to fix up 400ex oem muffler this week and start a new front fender stay.
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Discussion Starter · #20 ·
Test fitted fenders on my very old 3.2 gallon Clarke tank. I had fixed up its mounts a few months ago since they all egged put. Front fender stay was started. I had to remove my relocated front battery but will find a spot for it once the fender stay is finished Monday. Frames soon ready for powder once the battery placement is done again!
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