Suzuki dr 800 Tracker

[Fab Tanks]

Hi all one of the projects I am building at the moment is a street Tracker out of a suzuki dr 800 this is going to be my local hack so I thought I would build something a little diffrent it is going to have forks from a ktm and the swingarm from a early buell that is going to be widened and extended by 3 inches it will run a 240 rear tyre and the main frame and rear subframe will be altered and strenghend as the original frame wasnt up to the job of taking the alterations and to finish it off I will make the seat pan and tank from aluminium here are some photos of what I started with.

[DuckHunterJon]

Subscribing to this.  Always wanted a dr big!  Wish they weren't so hard to come by.

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[guernz]

I seen some of your sheet metal work on your other post. Stoked about seeing some progress on this. 

[Fab Tanks]

Here we go with the swingarm mods first I built a jig to hold the arm sections in place once they had been had cut I extended the arm by 70mm and widend it by 35mm in total I used some 80mm tube with a wall thickness of 10mm I turned the outside edges down by 5mm so the centre section would fit into the cavity of the arm once I had tacked the tube in place I slotted the top and bottom of the arm by 30mm and and slotted 10mm plates that were welded in to both arm sections and to the tube in the centre.

[VonYinzer]

Awesome

[smv]

herro.
signing up.

[Fab Tanks]

Here are a couple of photos of the swingarm progress.

[Caf'd Out]

Massive upgrades to stock parts to make them wild and crazy?! Got my tickets and popcorn. Roll film.

[Fab Tanks]

Hope youve got lots of pop corn Caf,d out this could take a while here is the swingarm almost completed im going to be putting another two holes each side later on in keeping with the retro look once ive completed the frame build

[guernz]

Thats crazy. Looks awesome.

[Fab Tanks]

Well did a bit off a mock up to day before I start to cut the frame  .

[Caf'd Out]

Well would ya look at that! Never seen someone clean up their welds quite so nice. Bought 5 boxes of popcorn with 6 bags in each. That be enough ya think? Say, is that rear sprocket custom? You make it?

[GreatDane]

Unbelieveable skills! Looking forward to follow this build!

[johnu]

Nice one, this is a great build!

[Fab Tanks]

Hi Caf,d out the rear sprocket is a blank it comes with the teath cut and a 1/2 inch hole in the centre its yet to meet up with the drill press. Progress up date on frame mods ive cut the frame and mounted whats left on the jig so far photos below