Big Red rebuild project has started. Lots of work to do..........(Long. Many pics.)

[TheRealFatShady]

Figured I'd post some pics up, but don't expect a finished product anywhere in the near future, lol.

Well, I started with a MAJORLY rough 1985 250ES Big Red. Was beat to hell, and didn't run. Carb spray + new plug + a bunch of kicks and it ran, but not great.

Pics when I got it:
http://i21.photobucket.com/albums/b253/videogamer2005/Big%20Red%20Project/0531001919a.jpg
http://i21.photobucket.com/albums/b253/videogamer2005/Big%20Red%20Project/0531001911a2.jpg
http://i21.photobucket.com/albums/b253/videogamer2005/Big%20Red%20Project/0531001910.jpg
Some problems

1. Seized choke plunger
2. Gas tank was half JBweld (on the TOP side!!!)
3. Seat all torn
4. Frame filthy, rusted, caked on gunk
5. No fenders except crappy 110 fenders zip tied to the TOP of rear rack. No battery. No brakes. No reverse cable.
6. Rack welded to it, no pivot to lift up for battery access
7. Rims all bent up
8. Exhaust covered in tinfoil
9. Engine smoked, rings likely. And the engine was covered in grime.
10. No toolbox lid, toolbox missing chunks

lots of random crap welds and broken bolts/tabs, small pieces missing, etc. All bolts were rusted, and/or seized in place.

Well, cost was an issue so this IS NOT going to be an 'OEM' inspired mint restoration. But I do have some hope for it. It's going to be a budget build, where the fenders will come later, as will HOPEFULLY an extension and lift.

Done so far:

Stripped EVERYTHING down. Engine/rear end/front end off, left just a bare frame and rear rack.
Dropped this off at my buddy's house for weld removal, cleaning, resurfacing, and paint.
http://i21.photobucket.com/albums/b253/videogamer2005/Big%20Red%20Project/P8230373.jpg
http://i21.photobucket.com/albums/b253/videogamer2005/Big%20Red%20Project/P8230374.jpg
http://i21.photobucket.com/albums/b253/videogamer2005/Big%20Red%20Project/P8230377.jpg
http://i21.photobucket.com/albums/b253/videogamer2005/Big%20Red%20Project/P8230376.jpg
http://i21.photobucket.com/albums/b253/videogamer2005/Big%20Red%20Project/P8240379.jpg

Got a TRX300 engine + carb + wiring
Swapped the right angle drive from the ES parts engine, just need to drill out a small hole and bolt it back in.
No pics on that yet.

For a small task, we decided to clean up the hitch before putting in on my SX. This is my cousin applying aircraft stripper and then primer from a spray can. I see the runs, will be fixed before calling the job done.
http://i21.photobucket.com/albums/b253/videogamer2005/Big%20Red%20Project/P8240381.jpg

Look at this!!! I have since used an angle grinder and bench grinder to get those beads off. Do not look factory, and I don't see why the previous owner would have welded there???
http://i21.photobucket.com/albums/b253/videogamer2005/Big%20Red%20Project/P8240389.jpg
I grinded off maybe 90% of it. The rest wasn't physically possible with a 4.5" wheel, just need something smaller on a drill but it's directly behind the bolt for the ball, so it's fine.

And the frame/rack I dropped off at my buddy's house....well he went to work with a grinder, sandpaper, primer, glazing putty, wire wheel, and oven cleaner. Got the rear rack off after grinding off a bunch of welds....man I hate idiots with welders!!!!!!!!!!!!

Here is a sample of what it all should look like: (Yes the pitting in the rear will be addressed as well)

http://i21.photobucket.com/albums/b253/videogamer2005/Big%20Red%20Project/P9050401.jpg
http://i21.photobucket.com/albums/b253/videogamer2005/Big%20Red%20Project/P9050400.jpg
http://i21.photobucket.com/albums/b253/videogamer2005/Big%20Red%20Project/P9050404.jpg
http://i21.photobucket.com/albums/b253/videogamer2005/Big%20Red%20Project/P9050403.jpg
http://i21.photobucket.com/albums/b253/videogamer2005/Big%20Red%20Project/P9050402.jpg

So, there's still a lot to do, but the rear brakes, 300cc engine, wheels and tires (have some sick mud and snow tires) and frame should be all set soon. I was thinking a gloss black automotive paint for the tank and frame but I do sort of like the primer black that's on there now.

What do you think? May camo the tank. But not sure on frame color.

Sorry for the long, long read. Hopefully this will encourage me to finish quickly!

[Dirtcrasher]

Those beads look like a typical "Arc Welder" with someone claiming they can weld. I think he welded there to fit a bigger hitch or fatten the surface it mounted to for carry heavier loads, maybe the wife and kids bodies :)

Keep it up!!

P.S. - I'm out of CO2 till next week so no gussets on the X frame yet, soon to come and pics will be shown :D :beer

[TheRealFatShady]

Ok, I will buy pegs and bring the heel guards if I can, I want those on as well. Will bring a set for you if you're still interested in that as well.

If you want to fatten that surface on that hitch, cut a piece of steel in a square, put on on top, drill a hole the same size as the ball's hole, then weld that plat to the bottom or top of the hitch. Don't just add junk beads that don't strengthen the metal....I hate people like that. You should have seen the trailer 'welds' we worked on this week.....rivets were the better choice.

[Dirtcrasher]

Yes, hook me up! I'll take it in consideration for all the work I do for you.....

I was looking today, I have your frame, caliper and cylinder head, I just hope your valves seal OK, Wish I could get you a cam and hardfaced rockers!! :lol:

Call me anytime Ryan, I have to get CO2 gas early this week (for the Mig welder) and I'll make that 350K frame basically INDESTRUCTABLE!!

How are the truck doors closing and locking, did tyour brother at least say "THABNKS"??!! :lol:

[PAPA250r]

My votes on gloss black for frame

Nice to bring one back to life

[harryredtrike]

how was the diff?good shape?she is coming along well

[bobotech]

Very cool budget resto. I would have gladly picked up that trike to fix up.

I would go with gloss black too.

[TheRealFatShady]

Will probably go gloss black. Will use automotive paint, also hoping to do my 350X parts, after the frame is made white. Black and white theme for that. Not sure on the BR scheme yet.

As far as the differential, it worked, meaning I could drive the BR. But beyond that, I haven't even inspected it yet.



Steve: Actually they were thankful...had to move people 4 times with the box truck, mostly college kids. Two trips to Boston to do it. So they were real glad that door latched!!! And my buddy (one who has the BR frame) used to be an NDT cert. welding inspector I believe, he liked those welds as well.

[MonroeMike]

Good work on the project so far.

[Dirtcrasher]

I like how you paint around the dirt Ryan :lol:

[aldochina]

i have a much nicer frame you can have. just come get it. looks like quite a project , enjoy!