250-500cc '96 WXC 250 build/restoration

don't discount oxy acetylene... takes skill, but that skill carries over very well to other forms of welding...

I've got a torch from WWII, regulators that are older than I am... the stuff lasts forever if taken care of.

that being said, you can get a quality used MIG pretty affordably if you're patient. stick with a Miller, Hobart (made by Miller) or Lincoln: parts/consumables are easy to find. I've got a Hobart Handler 210 at home that I really like...

bought a Hobart Handler myself, nice unit

The other problem I have is that at the moment I'm renting a house. There's only questionably wired 120V in the shed.
Once I buy a house, I'll probably upgrade my welder if I can get 240V in the garage.

240 on a proper circuit makes all the difference in the world...

i used to live in a rental and ran my welder off of the 240v dryer outlet. the laundry room was conveniently also the welding room

cant find these anywhere.... just need one
anyone have a source? if not i'll just machine some, but i'm lazy so would rather not...

Husky part number 8000 73500

funny but i have a spare set of 92 cases for a 360, well actually the engine, but, the same bushing has a different part number than 1993-2002, i guess they changed a few things in 93
sorry but don't have, must be a set somewhere, ebay, craigslist etc.

apparently my googlefu has been sucking... motosport.com & Halls has 'em... 1994 through 2013 is a pretty good run for a part

and evilbay for the swingarm bolt... almost looking like the bike is gonna go back together soon!

yeah, youll find theres a few things like shifters and pegs that they ran for years. cant wait to see it start going together. just went thru all this with my 95. i started in a lil better place tho, so i give you credit.

not the most exciting thing, but i'm stoked...

a replacement for the Grade 5 hardware store swingarm bolt... an actual metric Husky part:



side note: seems that damn near every husky from 1993 through 2014 used the same bolt.

and a lot of things were implemented in 95, that lasted a while. bike sure looks alot better with that swinger pivot and white paint!

oh, yay... the clutch cable mount is broken on the case... sure, why not.



i'm debating either weld it, with the cases together as is...
or cut the rest off, machine a stop and drill/tap the case...

leaning towards the later

Crap, take it apart get it welded re drill the hole, or leave it and put a bit of retaining wire on a washer too nearest bolt to hold it in position.
Looks like it will still work, but its not right.

i'm a welder, so that part isn't difficult...

but it just occurred to me that i may be over thinking the whole thing: old Yamahas just have a metal bracket that bolts onto the jug. i'm gonna make a bracket to drop off of the jug bolt in that photo. easy peasy...

yeah, you see that from time to time. i think part of it is the jammig the cable does against the coolant hose as well. a crappy setup right in that area...

yankin the bars completely off with a UTV will break that thingie

getting closer...
my local hardware store is an awesome resource for metric fasteners... 12mm 10.9 in damn perfect shoulder/thread length for the linkage. picked up a bunch of 6, 8, 10 & 12mm in 10.9 and stainless to replace most of what was on the bike.

radiators have had some abuse, but both pressure test just fine so i'll run 'em.

oh... any idea what the stator output is (or should be)?
i haven't measured yet...

damn head steady that came on the bike was some crap 1/8" x 1" steel that likely did nothing...
used one on ebay for $20...
or rummage through the scrap pile for some T6 aluminum...

template out of cardboard, transfer to material (dammit, out of dyechem) and cut the aluminum:



transfer punches come in handy for lots of things... transferring the hole locations from the frame/head... centering the drill...


hit the edges, radius the corners on the sander...


boom. new head steady...


not bad for 22 minutes, start to finish. half of that was spent trying to figure out where i put my coffee.
looks heavy, but weighs less than kate moss' left tit. normally i'd bore a bunch of speed holes in it, but only had a bit of time before the kids woke up... maybe later.

looks like ur gettin close