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Ground up challenger clone http://www.pilotodyssey.com/PO/viewtopic.php?f=5&t=20487	Page 1 of 3

Author:

Tylerthefabricator [ Tue Sep 01, 2020 1:10 pm ]

Post subject:

Ground up challenger clone

Hey guys, new member and first post. Thought I'd make a thread for my project because I know I'll need help in the future. So I bought a 77 fl250 last winter for 100 bucks. motor (( Internal Combustion Engine ? )) was seized and frame out of square from a front end impact. Plan was to fix it but one thing led to another and now I'm building a challenger frame and just recently picked up a good 83 Engine with electric start. I have messed with a few 4 strokes but this is my first 2 stroke. So I know I'll have questions later on. Anyways I figured I show my frame progress. I'm just going off pics online and the original fl250 for dimensions so it's close but not a exact replica. Let me know what you guys think? I don't know how to post more than 1 pic tho.

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Author:

Tylerthefabricator [ Tue Sep 01, 2020 1:15 pm ]

Post subject:

Re: Ground up challenger clone

Front end shot. Yea that's a fl350 steering wheel. Hopefully can make it work on this.

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Author:	canadian oddy [ Tue Sep 01, 2020 1:28 pm ]
Post subject:	Re: Ground up challenger clone
Welcome. Nice work !! It looks like you're a skilled fabricator. To add more than one picture you just continue what you did when adding the first pic. You go to the "Browse" button and select another file. Then click "add file" button. Repeat. You are limited to adding 6 or 7 pics at one time though. CO

Author:	Tylerthefabricator [ Tue Sep 01, 2020 1:35 pm ]
Post subject:	Re: Ground up challenger clone
Thanks do it for a living. That's what I thought but my phone was stuck on the loading image page. Thanks tho I'll try again next time.

Author:

Tylerthefabricator [ Wed Sep 02, 2020 4:20 pm ]

Post subject:

Re: Ground up challenger clone

Some close up shots. I used the original axle and cut the ends off and then turned down the ends to fit 7/8ths Dana Spicer u joints and then cut 1/4in key ways in them. I hope the keys are enough. I'd prefer spines but have no way to cut them. Then turned down the e brake side to accept a 1in bore axle bearing. Then made some stub shafts same way and then bored/ keyway in the original hubs. Also all brand new motor (( Internal Combustion Engine ? )) mounts and here's some pics how I mounted them. Not how challenger did it but I hope it works the same way.

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Author:	canadian oddy [ Wed Sep 02, 2020 4:45 pm ]
Post subject:	Re: Ground up challenger clone
Should be ok if you don't land with the power on. Quarter inch does seem light though. As long as the fit is real good and not sloppy it should be ok. If you do roll a key you can always cut another keyway. You got 4 shots at it. Tack weld ?? By the way very nice work there. That's not an FL250 anymore. Looks like you just built a whole new buggy. CO

Author:	Tylerthefabricator [ Wed Sep 02, 2020 5:32 pm ]
Post subject:	Re: Ground up challenger clone
Yea I was limited with the u joints available and the original axle thickness. Tacking it would do the trick or go the extra mile and broach and cut another keyway 180 degrees of the other one. Getting close to trying to start this 83 motor (( Internal Combustion Engine ? )) on the table soon here. I bought a full new wiring harness, coil and a 28mm mikuni. Also the electric start kit that was on it was missing the starter, harness and solenoid so I bought those too. Your right not much is left of the old fl250 and almost everything is new. Its going to be a brand new vintage Honda from the 80s built in 2020. Haha

Author:	Garemie [ Thu Sep 03, 2020 1:05 am ]
Post subject:	Re: Ground up challenger clone
Impressive work! Thanks for sharing.

Author:	ridgerun [ Thu Sep 03, 2020 9:26 am ]
Post subject:	Re: Ground up challenger clone
I may have some axles for the Challenger set up. Got lots of parts when I bought parts hoard. Lots of fl250 stuff. Don't need the fl250 stuff.

Author:	ridgerun [ Thu Sep 03, 2020 9:28 am ]
Post subject:	Re: Ground up challenger clone
Also have a center mount fl250 transmission.

Author:	hoser [ Thu Sep 03, 2020 2:39 pm ]
Post subject:	Re: Ground up challenger clone
Nice work Here is a site search for Challenger if you haven't done one yet best viewed with a computer not cell phone https://www.google.com/search?ei=njdRX8 ... CAw&uact=5

Author:	Tylerthefabricator [ Thu Sep 03, 2020 4:37 pm ]
Post subject:	Re: Ground up challenger clone
You have no idea how many times I've looked at your old challenger build! By far some of the best pics for reference out there. It has been extremely helpful. I have taken a break on the actual frame and started messing with the motor (( Internal Combustion Engine ? )). Now on to one of my first of many problems with this motor (( Internal Combustion Engine ? )). I was doing a leak down test before even trying to start it and it wasn't holding pressure at all. Sprayed soapy water and noticed it was coming from the exhaust manifold. So I tried tightening the 4 bolts a little farther and then realized I stripped and pulled one right out. Looked closer to find someone has put helicoils in there and now one failed and I don't really trust the other ones. Anyone have this issue? What would you do? Bigsert? Weld and retap if possible? I do have the jug from the 77 that was seized but it would need to be bored but the threads are all good. Should I waste time trying to save this jug? Thanks

Author:

Tylerthefabricator [ Thu Sep 10, 2020 5:00 pm ]

Post subject:

Re: Ground up challenger clone

More progress... And found some oversized hole thread inserts for my exhaust manifold bolts. Went alot better than I thought it would and now passes a leak test! Got the rear of the frame bent and tacked up and it is finally looking like something! Those rear hoops with the large bends really set the challenger apart from other buggy's and wanted to get them right. I really need to invest in a tubing notcher but I'm getting pretty good at doing it by hand now. Next step .. trying to start this motor (( Internal Combustion Engine ? )).

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Author:	canadian oddy [ Thu Sep 10, 2020 5:35 pm ]
Post subject:	Re: Ground up challenger clone
WOW that's sweet. If you got a problem with those tube notches then I would have to say that you're way to fussy. You should see some to the crap I filled with weld. CO

Author:	Tylerthefabricator [ Sun Sep 13, 2020 8:25 pm ]
Post subject:	Re: Ground up challenger clone
Thanks might be alil bit. The goal is to tig weld the whole frame so I'm trying to keep gaps at a minimum. Also to keep this thing as light as possible. All the main tubing is 1.25 x 083 wall DOM and the bracing and bumper and side bars will be .75 x .083 wall which I got from the challenger add. Im not sure how much it will weigh once everythings on there but the challenger pamphlet says the frame weighs around 125lbs. I've never driven a fl250 but I'm sure I'll want to go faster once it's all done and driving.

Author:

Tylerthefabricator [ Thu Oct 01, 2020 5:03 pm ]

Post subject:

Re: Ground up challenger clone

Made alot of progress. Beefed up the motor (( Internal Combustion Engine ? )) mounts and boxed in the j arms with some 14 gage. Most of the 1.25 tubing is done on the frame and finally found a real seat! Slightly used but really comfortable. I was using that plastic Jaz seat just for mock up. I made the frame a tad longer and taller than the original to fit a 6+ foot person comfortably. I also had to tilt the steering column up a bit to clear the longer fl350 brake handles. Started making a custom gas tank template with cardboard and getting ready to start rear suspension!

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Author:	Kuma [ Thu Oct 01, 2020 5:29 pm ]
Post subject:	Re: Ground up challenger clone
looking good, as a suggestion, you should do some bracing for the roll cage, if you ever need it you don't want it to fold

Author:

Tylerthefabricator [ Tue Oct 13, 2020 8:21 pm ]

Post subject:

Re: Ground up challenger clone

I'll have to do that. Here's where I'm at now. So close to having a roller!

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Author:	hoser [ Fri Oct 16, 2020 11:13 am ]
Post subject:	Re: Ground up challenger clone
Looking good! You seen all of these on the Challenger yet? https://www.google.com/search?ei=R7iJX6 ... CAw&uact=5

Author:

Tylerthefabricator [ Fri Oct 16, 2020 1:13 pm ]

Post subject:

Re: Ground up challenger clone

Thanks for the link and yes I've scoured the internet for info on challenger. Every pic helps when trying to replicate something. Now that it looks like it's supposed to I need to make sure it works like it's supposed to. My first set of rear springs were a fail. Frame wouldn't come off the floor! I have a stiffer set now that I think will work.

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Author:

Tylerthefabricator [ Fri Oct 16, 2020 6:10 pm ]

Post subject:

Re: Ground up challenger clone

That's better... Think these springs will work. These shocks are off a 99 artic cat zr 600. I had them rebuilt, recharged and new shafts installed. Most importantly they have preload and compression adjustment.

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Author:

Tylerthefabricator [ Sat Oct 31, 2020 4:12 pm ]

Post subject:

Re: Ground up challenger clone

Suspension set up. Also finished up the gas tank. I wanted to use aluminum but we only have really thick stuff at my work so I used 16 ga. Stainless. Have a reserve line set up just like the original tank too. Made the fuel fill neck cuz it was just too awkward to fill with a gas tank inside the cage.

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Author:	canadian oddy [ Sat Oct 31, 2020 6:39 pm ]
Post subject:	Re: Ground up challenger clone
That's high quality work right there. Nice job. CO

Author:

Tylerthefabricator [ Sat Oct 31, 2020 8:50 pm ]

Post subject:

Re: Ground up challenger clone

Any guesses on fuel capacity?

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Author:	canadian oddy [ Sat Oct 31, 2020 9:04 pm ]
Post subject:	Re: Ground up challenger clone
Tylerthefabricator wrote: Any guesses on fuel capacity? My guess is 8 gallons. CO

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