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BobPA BobPA
10/31/2017 7:19 PM

My initial post will be a bit long and picture filled. The bike will hopefully be done by January or so.

I bought this bike In May of last year as basically a bone stock, unmolested 2003 KX 125. I rode it until the fall and then sent the engine out to Eric Gorr for a 144 kit. Well after 7 months of back and forth, I had myself a running 144 on full race gas. I only got about 8 hours on the bike this year and have decided to build her up.

Current plans
Touch up some cylinder port work for some more ponies
Scalvini Pipe (Ordered but will not be here until December sad )
Green Powdercoat frame and subframe

The photos will do more explaining then my typing.....

This is how I bought it...
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I will be making a custom silencer using the old school stinger tip...I have always loved the look. I got this one off of eBay for $15 from a '99 KX, and was really hoping the end cap would rivet right on to my current PC silencer. But, the bodies of the silencers are different sizes. So this is going to take a bunch of cutting and welding to make it right (more pics to come). I actually will not complete this until my Scalvini shows up, so I can mount it and get the alignment perfect.

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These are my graphics. Based off of a 1989 KX, should go well with the green frame and swingarm. Also a blue seat cover.

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Wheels will be stock 09+ KX hubs with a minor polish and some gold hoops. Have the rear spokes and rim, having a tough time locating a hub...

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Tomac and/or Anderson for 2020.....

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BobPA BobPA
10/31/2017 7:25 PM

I got a set of, what I was told, were like a 'B' kit fork from a 2006 KX250f. Also the matching PC clamps for the forks. I will be making a step by step instruction on how to modify the steering stop to fit modern four stroke clamps. The DLC coating adds a nice touch.

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Rebuilt the forks tonight actually. Pretty dirty inside as you can see. I called PC and they are too lazy to look up the old records, as the forks still have the name and last date of service on them. Anyone know exactly what they are?


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Tomac and/or Anderson for 2020.....

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BobPA BobPA
10/31/2017 7:26 PM

Using this as a base for the look

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Tomac and/or Anderson for 2020.....

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ledger ledger
10/31/2017 9:22 PM

I like where this is heading already, looking fwd to the....step by step steering stop modification. The green frame/ blue seat cover and graphics along with /gold rim's will make this bike a head turner, great idea and a great bike. I'm in. wink

There's something happening here, what it is ain't exactly clear.

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KDXGarage KDXGarage
10/31/2017 10:12 PM

COOL! Good luck on the build. It was a very nice looking starting point!

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RoostBuckets RoostBuckets
11/1/2017 3:33 AM

Talk about a panty dropping roost bucket feeding horse power wagon.

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RyanLester761 RyanLester761
11/1/2017 8:00 AM

I like your plan here. Classy. And some nice parts there... besides that silencer. Haha. I ALMOST considered buying that one. I watched it on ebay too.

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BobPA BobPA
11/1/2017 9:21 AM
RoostBuckets wrote:

Talk about a panty ...more

Holy shit he signed up....

Tomac and/or Anderson for 2020.....

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BobPA BobPA
11/1/2017 9:22 AM

Thanks for the kinds words guys,

Ryan, I eye balled that silencer for a while. Trust me, it looks better in pictures than in real life haha, she is rough. No big deal though, a bit of elbow grease and a welder and she will be like new.

Tomac and/or Anderson for 2020.....

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RyanLester761 RyanLester761
11/1/2017 9:29 AM
BobPA wrote:

Thanks for the kinds words ...more

Good luck on that. I'll be following.... smile

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RoostBuckets RoostBuckets
11/1/2017 10:31 AM
RoostBuckets wrote:

Talk about a panty ...more

BobPA wrote:

Holy shit he signed up.... ...more

Just following to see what motor work you do... seeing if you'll make a faster machine then LWR#59 #roostbuckets

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HenryA HenryA
11/1/2017 12:02 PM

Ooooh, this look on a KX125 is something new! Exciting stuff, good luck!

#1
KX125

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BobPA BobPA
11/2/2017 7:32 PM

So I did a quick mock-up of the triple clamps and forks tonight. You can see by the pictures what needs to happen. These marks were just quick measurements to see what I am working with, but gave me a good idea of what needs to happen.

I measured and marked the center of the OEM triple clamp. Then, ran the clamps from steering stop to steering stop and marked where the center line landed.

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The just took some quick measurement off of the radiator. Most of these are really just getting it "close"

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I then bolted on the new clamps and forks and right away it is obvious what needs to be done. I marked the center of these clamps and lined it up with my mark on the frame with the previous clamps. You can see the steering stop needs to be about 0.335" wider on each side, and also lower on the head tube.

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You can see the fork is now the steering stop on the frame, which is clearly no good.

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Getting a bit ahead of myself here

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Tomac and/or Anderson for 2020.....

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KDXGarage KDXGarage
11/3/2017 10:01 AM

Very good planning!

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ledger ledger
11/4/2017 7:30 PM

That looks great !! Gotta ask, just how large a Kawasaki decal is in the 6th pic down ? Just wondering....wink

There's something happening here, what it is ain't exactly clear.

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BobPA BobPA
11/4/2017 8:30 PM
ledger wrote:

That looks great !! Gotta ...more

48"

D'Cor makes them, I believe they are around $20. Got is from Western Powersports....Going in my pool table room haha

Tomac and/or Anderson for 2020.....

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Kx125rider Kx125rider
11/5/2017 12:25 PM

Love the gold rims and old school look in general.

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BobPA BobPA
11/6/2017 1:11 PM
Kx125rider wrote:

Love the gold rims and old ...more

Thanks. I believe this may have been your old bike?

Tomac and/or Anderson for 2020.....

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Kx125rider Kx125rider
11/6/2017 3:35 PM
Kx125rider wrote:

Love the gold rims and old ...more

BobPA wrote:

Thanks. I believe this may ...more

Yea good to see its in a good home, its gonna turn out sick.

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twotwosix twotwosix
11/8/2017 10:38 AM

Looking great. Any plans for the shock?

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BobPA BobPA
11/8/2017 4:05 PM
twotwosix wrote:

Looking great. Any plans ...more

Thanks. Nothing at the moment besides bumping up the spring rate for my fat ass. Shock works well actually. I would not be opposed to running some PC dog bones though.

Tomac and/or Anderson for 2020.....

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Sidecar Sidecar
11/13/2017 10:17 AM

Gonna look nice, the gold wheels will look awesome!!!

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BobPA BobPA
11/13/2017 6:54 PM
Sidecar wrote:

Gonna look nice, the gold ...more

Thanks, did some limited work today. I lawn darted two weeks ago and busted up my arm pretty good. So I have been feeling like shit with antibiotics and haven't touched anything. My arm is working enough to resume this week though.

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Looks like my new steering stop will have to be at least 1.560" total. I got this by measuring the OEM stop at 0.890" and adding the 0.335" per side needed per my prior measurements. Obviously going to start on the larger side...easier to remove material than to add haha.

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Here is a quickie of my arm. Crashed in a shitty roller section after it rained, somehow got these bullet wounds haha. As they were scrubbing the shit out of it the the PA shot water in the big hole, and it came out the smaller hole...you should have seen my girlfriend squirm. Seeing as they connected it made for an extreme likelihood for infection.

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Tomac and/or Anderson for 2020.....

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ledger ledger
11/14/2017 12:36 AM

I kinda figured that little boo-boo had you down for a few day's (just mess'n). Glad to see you back working on the bike, I'm still waiting on the powdercoat guy to get his shop set-up, if he can't get it together soon, I'll paint it myself with automotive paint. Anyway, glad you didn't get too banged up, heal up brother.

There's something happening here, what it is ain't exactly clear.

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Markee Markee
11/14/2017 4:34 AM

Nice, can't believe I've missed this thread.

Doing something similar on my 500 as far as the shroud graphics go, but my build will be black/green only with yellow backgrounds.

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BobPA BobPA
11/15/2017 6:56 PM
Markee wrote:

Nice, can't believe I've ...more

Nice, what color wheels and frame are you going with?

Tomac and/or Anderson for 2020.....

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BobPA BobPA
11/15/2017 7:06 PM

This post is for KDXgarage. Basically all I did here was cut a piece of 1/4" think steel, used the grinder to make it fit the frame, welded her on. The pictures pretty much tell the story. It is a simple process, but still takes time and patience. I used a MIG welder because the TIG was out of gas lol. When using a MIG I did not run a full bead all at once. This was to minimize the heat going into the headtube, while still getting good penetration.The bottom of the headtube is actually quite thick and would probably be fine running complete beads. I did not run the beads all the way to the edge because I thought I may have to file the steer stop a bit shorter.

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You can see here that I filed the stop so the triple clamp would land flush. I guessed on the angle when I initially made the piece...But, it did not land perfectly flush.

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Tomorrow night it gets stripped down to the frame, and off to the powdercoaters on the weekend.

Tomac and/or Anderson for 2020.....

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ledger ledger
11/16/2017 12:04 AM

Nice work. Looking fwd to seeing the frame after the fresh powdercoat....carry on.

There's something happening here, what it is ain't exactly clear.

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KDXGarage KDXGarage
11/16/2017 2:10 AM

Thank you very much for the posts and great pictures. I appreciate it! It looks great.

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BobPA BobPA
11/16/2017 6:38 AM
KDXGarage wrote:

Thank you very much for ...more

TIG will do a much "prettier" weld if you are concerned about that. I just wasn't feeling the half hour drive to refill the tank...took the last mans route

Tomac and/or Anderson for 2020.....

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