collapse

www.dimecitycycles.com

www.cognitomoto.com

https://www.townmoto.com/collections/vanson-leathers

www.speedmotoco.com

www.CITYLIMITMOTO.com

www.jadusmotorcycleparts.com

www.lostapostlejewelry.com

www.sparckmoto.com

www.pistonsociety.com


Author Topic: Project Ground Pounder -1981 Suzuki DR500  (Read 12241 times)

Offline Kanticoy

  • DTT SUPPORTER
  • *
  • DTT BOTM WINNER
  • *
  • Posts: 5057
  • Mad Science!
Project Ground Pounder -1981 Suzuki DR500
« on: Oct 16, 2018, 11:23:19 »
So some of you know I turned a pile of DR500 that my buddy Jared got for $100 into a dual sport over the past several years. MK2 of that bike warranted a new titled frame from a later model DR650 so it left me with a nice titled frame for an 81 DR500. Ive had this idea kicking around in my head for a while to build a hard tail and have collected a few parts over the years. A lightbulb went off and I decided that I would look for a motor and built my hard tail out of the remnants of the last build.

Fast forward to a couple of weeks ago where me and some buddies had a swapmeet spot for the Barbers Vintage fest. I told everybody before the weekend got started that the only thing I was looking for was a DR500 lump for a possible project. We were sitting around on the first day and a guy is pulling in with a trailer full of bike carcasses. My eyes lit up as he pulled in as I saw a fender I recognized. I waited for the guy to park and walked over and sure enough there it was: a 1982 DR500 frame and motor sitting there. It was meant to be as his swap spot was literally across the isle from us! $100 later and I was the proud owner of this:





The motor was free and it gave a good burble when I kicked it over. Ive had a set of leading link forks stashed away for this project for a while but when another two sets came up for $60 I had to grab those too:



The remnants of the old dual sport have been sitting outside the shop and after barbers wound down and I had a little free time I got to work. No turning back now! This is the titled frame:





Yesterday I had some time so I decided I would prep the frame and see what it would take to get the leading link forks on this frame. After a little frame clean up:





Turns out the stem bases for the forks are the same diameter, but the neck on the DR500 is much longer so it required lengthening the fork tubes after I pressed in the original DR500 stem. You can see where I cut the original tops off of the forks and added in some tubing extensions here.





After I TIG welded all of the puzzle pieces together it got me to here. Success!





The last project of the day was to add in some tubing to the rear of the frame to allow me to build off of it for the hard tail section. The original frame had some funky angles so it took a bit of math to get the fish mouths right to add in the tubing extensions but in the end it worked out well. Good place to build off of now:









That gets us caught up to current. Lots of parts trickling in as far as wheels, tank, tubing for hard tail, etc. Ill keep this updated as it goes!


I get not knowing, but I can't for the life of me understand not trying. It's only metal it can be fixed. Man up and risk a mistake in exchange for a lesson.
'


Offline canyoncarver

  • DTT SUPPORTER
  • *
  • Posts: 3946
  • 'hacking is learning'
Re: Project Ground Pounder -1981 Suzuki DR500
« Reply #2 on: Oct 16, 2018, 11:31:05 »
Glad you are putting this one up here man.  Chop on!

Offline Hurco550

  • DTT SUPPORTER
  • *
  • DTT BOTM WINNER
  • *
  • Posts: 3941
  • Keep er' Between the ditches
Re: Project Ground Pounder -1981 Suzuki DR500
« Reply #3 on: Oct 16, 2018, 11:34:24 »
this is stupid, and you're weird. but ill watch anyways.

side note, pretty sure you could fabricate the entire hardtail out of the old rack on the mk2.

also this isn't stupid, its cool....

but you're still weird.
"If you just picked up a drug habbit instead of a kawasaki triple at least you could get high while you waste money"
~ bradj
1988 tw200, the swamp donkey: http://www.dotheton.com/forum/index.php?topic=75455.0
2006 Suzuki DR650 Adventure monowheel trailer build: http://www.dotheton.com/forum/index.php?topic=75033.0
1976 BMW R90/6 farkilitious: http://www.dotheton.com/forum/index.php?topic=74349.msg882477#msg882477
1975 RD350 Road Racer: http://www.dotheton.com/forum/index.php?topic=70652.msg833688#msg833688
1976 GT250 Rebuild: http://www.dotheton.com/forum/index.php?topic=64973.new#new
Full Custom Pit Bike: http://www.dotheton.com/forum/index.php?topic=66954.new#new
1971 Yamaha 90cc twin HS1: http://www.dotheton.com/forum/index.php?topic=70498.0
"much ingenuity with a little money is more profitable and amusing than much money without ingenuity" - Arnold Bennet

Offline pidjones

  • Posts: 942
Re: Project Ground Pounder -1981 Suzuki DR500
« Reply #4 on: Oct 16, 2018, 11:34:59 »
Excited to watch this! Love me some thumpers.
"Love 'em all.... Let God sort 'em out!"

Offline Sonreir

  • Moderator
  • DTT SUPPORTER
  • *
  • Posts: 11272
  • Oregon
Re: Project Ground Pounder -1981 Suzuki DR500
« Reply #5 on: Oct 16, 2018, 11:53:58 »
Following along.
Sparck Moto - http://www.sparckmoto.com

Audaces fortuna iuvat.

1977 Honda CJ360 - Caf SOS - Stage One, Caf SOS - Stage Two
1976 Puch Maxi - APuchalypse Now
Suzi T500 Cobra Resto

Custom Gauge Graphics
Custom Wiring Harnesses

DTT Red, White, and/or Black 360 Club - Better than those Blue guys

Offline Maritime

  • DTT SUPPORTER
  • *
  • Posts: 9806
Re: Project Ground Pounder -1981 Suzuki DR500
« Reply #6 on: Oct 16, 2018, 11:56:38 »
Signing up. Looks rad so far.
The GL Rebirth: http://www.dotheton.com/forum/index.php?topic=68337.0
CX500 Low budget Bobber : http://www.dotheton.com/forum/index.php?topic=43617.0
"Beer makes you feel the way you ought to feel without beer" -Henry Lawson
"Beer is proof that God loves us and wants us to be happy." - Thomas Jefferson

Offline Brodie

  • DTT SUPPORTER
  • *
  • Posts: 2537
  • Gold Coast, Queensland
Re: Project Ground Pounder -1981 Suzuki DR500
« Reply #7 on: Oct 16, 2018, 12:32:40 »
Rad. Can't wait to see what you make out of all this.
I'm not sure, but don't ask Brodie.

Way to many build and half done projects to list here.
Sr250, Gs750, Z50A, XV1100, A10, Z160A.

Offline Kanticoy

  • DTT SUPPORTER
  • *
  • DTT BOTM WINNER
  • *
  • Posts: 5057
  • Mad Science!
Re: Project Ground Pounder -1981 Suzuki DR500
« Reply #8 on: Oct 16, 2018, 12:56:43 »
this is stupid, and you're weird. but ill watch anyways.

side note, pretty sure you could fabricate the entire hardtail out of the old rack on the mk2.

also this isn't stupid, its cool....

but you're still weird.




Sent from my iPhone using Tapatalk
I get not knowing, but I can't for the life of me understand not trying. It's only metal it can be fixed. Man up and risk a mistake in exchange for a lesson.
'

Offline JustinLonghorn

  • DTT SUPPORTER
  • *
  • Posts: 6666
  • No Purple Hearts, No Blue Ribbons
Re: Project Ground Pounder -1981 Suzuki DR500
« Reply #9 on: Oct 16, 2018, 14:25:47 »
Choppers are stupid.
I'm going to eat your brains and gain your knowledge.

Into The Sunset, CB750 build

TT500 the Animal