Project Ground Pounder -1981 Suzuki DR500

The Jimbonaut said:
Love this bike! Just looking at it is an education - the crazy front end, the snaking exhaust, the restraint on leaving the tank battered and original...this thing is just the coolest ride. Kudos man, this bike's a riot.

Ditto. When I think of "motorcycle building" this is exactly what comes to mind.
 
cxman said:
put a uni filter on it to start

get your jetting in range ish then do the filter playing

I’ll give her a go, thanks for the tips man!

The Jimbonaut said:
Love this bike! Just looking at it is an education - the crazy front end, the snaking exhaust, the restraint on leaving the tank battered and original...this thing is just the coolest ride. Kudos man, this bike's a riot.

jordandogtown said:
Ditto. When I think of "motorcycle building" this is exactly what comes to mind.

Thanks fellas, I really appreciate that! I gauge the viability of a build by how creative it lets me be and how much fun I get to have during that creative process. This build is ticking all of the boxes so it’s time well spent. Thanks for following along guys!


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Got some more business done today. Powdercoated a batch of parts including the rear caliper bracket, the fender struts, and some superfluous other little bits. Next I had this piece of forward control shift linkage in the parts bin from an HD or something that I decided to turn into the rear brake stay. Had some nice grim joint ends and overall looks the part. Nice and rigid too. Turned down a frame lug out of steel and fishmouthed it to weld to the frame for the frame end. Then drilled and tapped it for M8. Works great.

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Next up I mounted up my tail light. Found a rad marker light from a truck cab probably from the 40s or 50s has a nice glass red lens and fits the fender contour nicely. Put a modern 1157 socket inside and got it all mounted up. Suits it quite nice!

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Thanks fellas! And Jimbo I LOVE my AT. First new bike I’ve ever bought and I can’t quit riding it. The perfect do-all bike. Nothing bad to say about it at all.


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Well played sir. Well played.

I like the light and the tucked in exhaust.
 
As soon as the winter slings its hook I'm going to pay a visit to the dealership where my friend works - they have an Africa Twin demonstrator there. I really want to take one out for a ride - love the look of the bike and from what I've heard it's a ton of fun to ride. You got yours in the right colour too 8)
 
The Jimbonaut said:
As soon as the winter slings its hook I'm going to pay a visit to the dealership where my friend works - they have an Africa Twin demonstrator there. I really want to take one out for a ride - love the look of the bike and from what I've heard it's a ton of fun to ride. You got yours in the right colour too 8)

I have a feeling once you ride it you’re gonna want to buy it. They’re awesome! And is there any other color but tricolor?
 
Kanticoy said:
I have a feeling once you ride it you’re gonna want to buy it. They’re awesome! And is there any other color but tricolor?

a 2016 tri-colour with DCT with 13K miles came up local for $10K CAD and if I had the $$$ it was mine. With gimp foot the DCT is a good option for me as I can shift with buttons or go full auto. It sold in 2 days. I was sad
 
The Jimbonaut said:
I'm sad for you Mike!

thanks. I did all the maths to try and get $10K together short of selling a kidney and couldn't. I can't buy that kind of stuff with Family money so was not going to pull it off. It was a great deal.
 
Didn’t get much done today but I did hack up a $5 auto zone turndown exhaust tip into a heat shield. Wanted something in that bend to keep me from sticking my shin into it. The curve looked right so I gambled on it and it fits perfect after a little grinder whittling and a drill press.
 

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Spent this morning building custom brake lines. I used stainless hose and stainless fittings and went to work.

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Next I welded tabs in the proper locations on the forks and frames to use aluminum hose clamps made for a pit bike to keep everything nice and tidy.

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Ended up with three tabs on the forks and left a relief bend that I covered in asphalt wire loom and heat shrink to keep things from rubbing and causing abrasions where the suspension works:

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Next I worked out the back. Basically the same scenario and ended up with 2 tabs:

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As she sits now. Really loving the stance of this thing:

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Dude, really nice work on running those lines. Looks tremendous.

Totally makes sense doing your own hoses in that setup. Did it require any special tools?
 
canyoncarver said:
Dude, really nice work on running those lines. Looks tremendous.

Totally makes sense doing your own hoses in that setup. Did it require any special tools?

Thanks man! No special tools. Look up the Magnum BYO (Build Your Own) brake parts. Really simple and really tidy looking installation. Just basic tools is all you need.
 

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