250-500cc '96 WXC 250 build/restoration

Probably done at a race meet with some blokes arc welder out the back of a van, seriously some people when theres a race on or coming up will do ANYTHING to race Its addiction simples.

Glad shes found a good home with you tho

I've been there, more than once. break something, do whatever it takes to still get to race.

gaffer's tape, structural use of zip ties, welded fork sanction once; that was awesome... forks would bottom and get stuck.

i zip ty'd a shock on my 81XC once

hahahahahahaahahahaha
do you have a picture by chance

that is where the redneck humor stuff comes from

NOPE GOOD THING THAT BOTTOM STUD IS ANGLED UP TOOK THE LOAD OFF UNLESS THE REAR TIRE IS OFF THE GROUND

You got yourself a real project there. It's worth fixing for sure & you can only make it better from the starting point you got. Awesome swing arm bolt. It's a crime what was done to that fine piece of machinery. I'm sure you will do it right. Will be watching along to see the progress.

gonna need some parts...

swingarm bolt & at least one of the bushings that sits in the case @ the swingarm

all 4 motor mount bushings (and hell, the bolts too)

luckily looking at the parts book, the same parts were used up to at least 2008 for both 2t and 4t huskies.

if anyone has any of it, let me know...

oh, and a right side number plate, but I won't hold my breath on that. DC if nothing else comes up...

TIG broken. Out of Acetylene. Wait! is racebike! is OK! MIG is good enough...

fix motor mounts & make a pipe mount.


fix the peg mounts:



nothing real exciting...
next is the steering stop (just flat out missing)...
then quick sanding/prep of the frame then bust out the ghetto powder coat (ACE hardware appliance "epoxy" enamel)

still need to get my hands on a swingarm bolt & the bushings

the steering stop on my 99 is missing too, pretty poor welding on those

Hey man, I just got into welding. I have a DC Flux Core Wire welder, and I never get welds that look that good. It's a combination of low quality equipment and low quality skills. Can't wait to see the finished product!

i would suggest ditching the flux core. its only advantage is welding where its windy, like in the middle of a field. you really want to use a gas mix with a wire welder.

looks like a good start. i have pretty good luck with the napa spray paints, just have to prep well.

agree on ditching the flux core: great for farm repairs, but not so great otherwise.

I prefer TIG and even Oxy/Acetylene over MIG, though MIG sure has its place. I run 75/25 (75% Argon, 25% CO2) for shielding gas, which makes a difference.

Im a mig monster so simple like me... Would like to tig but need welder so i can make my own custom bits.

put a steering stop on the stem (adjustable)
filled/drilled the wallowed out peg holes
motor mounts done
gave it a quick sanding, degrease/dewax
coat of white appliance epoxy...

That's the route I wanted to go, but I really didn't have the budget for TIG. And, couldn't find any used on craigslist for the two months I was looking. Actually there were some used ones, but they were all over $750. Way too much for me and my two welds a year. My buddy has a top notch TIG, so once he moves into a house and gets it out of storage, I can always borrow his for more precision projects.

if you've got the time and one near you, I strongly recommend a community college welding class. cheapest way to get great experience.

I took a few, years ago. led me to getting a bunch of certifications and a pretty good trade. one could do worse than being a welder...
(im not a career welder anymore, but kinda miss it)

Not career welder but do weld morgan chassis up for beer money, its satisfying doing a nice weld that requires no finishing thats when you know wire speed amps are all spot on. Very rewarding as it will be there for the duration of the cars life.

im not saying TIG, because they are very expensive for most people. im saying to go MIG. flux core is very difficult to weld properly with. mig is the same thing only you use a shielding gas and different wire. alot of times a flux core machine will convert easily to a mig machine, but its cheaper to just buy a mig to begin with.
TIG is a whole different setup than a wire welder and are nice but usually very expensive for the home user...a used mig setup can be had cheaply if shopped around.