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Cheifbootknocka
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1,944 Posts
Discussion Starter #1
You guys interested in seeing a non car build ? A full build of a streetbike converted raptor ? There's not alot of other places I would post this build other than my SF family :eek4dance
 

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Cheifbootknocka
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1,944 Posts
Discussion Starter #3
This story goes like this - My buddy started taking me on weekend trips to ride quads in the sand dunes in exchange for helping on some of his 4x4/car projects.

Originally he had an 02’ raptor 660. He purchased a blaster so he had a second quad, and myself or his nephew could ride that. I used to ride dirtbikes back in the day and I still ride streetbikes.

Quads in the sand are a who-notha’ level of fun (mad tv reference).

After a few trips he decided to upgrade to a raptor 700 and I got to ride the 660. Much better.
After a guys trip earlier this year with 6 quads and three dirt bikes outfitted for sand ….

One of which is a FZR600 carbed banshee.



I got back home and decided it was time to build not buy, a ride for myself.

I searched craigslist and cycletrader, every good deal was gone within hours.
 

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Cheifbootknocka
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1,944 Posts
Discussion Starter #4
I found a quad with a blown motor which was just perfect for me since I wanted to bore and stroke the motor to a 686 or 727.

I picked up this 01’ 660 for $500.00 and it came with 75% of a second motor. I got it back to a friends house until I could figure out how to tell my wife that I purchased a quad without talking to her about it, while in the middle of my GS300 build…





Start dismantling it in said friend’s garage





 

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Cheifbootknocka
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1,944 Posts
Discussion Starter #5
At this point I had been doing research for a few weeks and decided on which parts to go with.

The supporting mods for the original parts would require larger carbs and other supporting mods to make it reliable. Carbs are simple, but I look at them as difficult. Im an EFI and wiring guy.
I would rather hit the go button and… well… go.

My friends were trying to talk me into a streetbike conversion and I kept saying no.
While looking over the carcass at my buddies house we started to realize the quad had a bunch of aftermarket parts on it. Most of which I didn’t care for. A ghetto supertrapp muffler. A hydraulic clutch conversion… the bug hit me.

If I sell off all these crappy parts, and buy gaskets to build one good motor, I could sell the 660 motor and pay for some of the parts I would need for whatever direction I go.

My friends were sending me craigslist ads of other quads and streetbike motors...
I ended up looking as well...peer pressure is a biotch...found a guy parting out his race bikes/trailer etc. He had a spare motor from the previous season and wanted to clear everything out of the garage.

I assembled a stock motor, sold it for $400 within two days and used that money toward this impulse buy of the K7 gsxr 600 FI motor.
I didn’t want to do an R1 motor because I don’t feel that I need that much power on a quad.

Too much is almost enough you say… true story but not a necessity in this case.
Got the motor home and quickly realized there was zero hope of getting the motor to live in the frame without mods.

 

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Cheifbootknocka
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1,944 Posts
Discussion Starter #6
I’ve done tons of motor swaps and other crazyness but never worked on a chassis.
If I know one thing, its that once you cut the frame and it springs out of place – your hosed.

So I set out and learned about jig’s a little. For the purpous of this home brew quad, I built my own frame jig with steel frame and wood platform up on sawhorses.





I thought what the hell you only live once, so after a lot of measuring and test fitting I make the first cuts on the frame.





My buddy was sand blasting some parts while I screwed around with the frame



This obviously won’t work

 

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Cheifbootknocka
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1,944 Posts
Discussion Starter #7 (Edited)
The beginning of some front upper motor mounts to triangulate the frame



Trouble shooting the torchmate while cutting some parts for the mounts




To make these






This was the first time I’ve tig welded steel. After some recommendations from my a friend Ron R on the forums. I picked up a gas lens and got a little better at welding. Came up with this



For here



And here

 

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Cheifbootknocka
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1,944 Posts
Discussion Starter #8
With a jig to install them straight



A little fishmouth with a tube notcher





End result is left and right mounts






Mockup with cardboard then draft and cut some more mounts



 

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Cheifbootknocka
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1,944 Posts
Discussion Starter #11
Its done ! I rode it back in august ! WOOT
 

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Cheifbootknocka
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1,944 Posts
Discussion Starter #12 (Edited)
Lower motor mounts with a full weld so that tabs don’t just break off



Test fit to a lower tube which ended up being removed later



Some rear upper mounts which will have the upper shock mount incorporated into it.



Repurpose the original upper shock mount





 

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Cheifbootknocka
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1,944 Posts
Discussion Starter #13
After deciding to fabricate a air box over the ITB’s I decided to reinstall the upper frame.
I sleeved the upper frame rails



At this point I needed to figure out wtf I was going to do with the lower frame.





The oil pan is so damn deep on the K6-K7 motors that I needed to build the chassis around the motor.

I broke the rule of removing the frame from the jig. Though on the same token, that’s partially what the jig is for, to be able to put everything back as it was. Which it did, all of the parts I had mocked up still fit perfectly after I reinstalled them.
 

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Cheifbootknocka
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1,944 Posts
Discussion Starter #14
Getting pretty stoked by this time







With the frame being wider, I needed to inboard the foot pegs.
Again with the carboard mockup, draft, cut and fab



 

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Cheifbootknocka
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1,944 Posts
Discussion Starter #15
If im going to build this thing, its going to be overbuilt, opposed to being thrown together and/or underbuilt as most of these conversions are that I’ve seen.











 

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Cheifbootknocka
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1,944 Posts
Discussion Starter #19 (Edited)
Alex, no plans for FI....yet... that would have made the build easier due to laying out the exhaust/air box and intake.
This thing is plenty fast. I just have to gear it so I can hit some hills with more speed. Right now its gear so low all I do is spin 10 paddles.
Need some 12's even though I hate the way they look. Oh and yea, I love fab heavy builds as well. Thats my motivation for being a photo posting whore.
 

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Cheifbootknocka
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1,944 Posts
Discussion Starter #20
Tacked into place and mocked up



Once they were done I realized my brake pedal was all jacked up so I started hacking and patching the old one till I got it to fit right.



The look at it and said fawk this. Im not going to half ass this biotch. Drafted up a new one and built it from scratch



Nice fit

 
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