KX Guru Racing KtX500e Kawakaze electric start KX500 & KTM Chassis

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This is the front brake caliper mount as removed from the bike.
And when you think about it, removing the casting flash would cost a lot more money for the manufacture.
But for me.... I can clean and polish while watching the tube..

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This is after I removed the casting flash..

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Pretty rough

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Time for some polishing...

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Obviously I have a bit more work to do..

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Getting there.... But why so much work for a caliper mount?
I'm going to anodize it
The guy doing the work said the smoother I get it the better the job will turn out so....

Gettin closer..

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Just a wee bit more progress.

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One of the things about doing a conversion is taking things apart and putting them back together several times...
It doesn't pay to be impatient.
Since I want this bike to be right I'll take it apart as many times as it takes

Today we started off by getting some temp rear engine spacers made..

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The idea was to get the chain running true to the slider and the rear sprocket...
Mission accomplished.
Once we get it torn down again I will measure them and get some nice ones made..

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Next, we put the exhaust back on so we could see what the muffler was going to require..

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If it wasn't for having to mount the sub frame that hole position is perfect..

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Next we set up the custom Adam Millar billet VF2 reed with built in spacer..
We needed to figure out the air box situation..

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Everything is looking good so far..

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But here is the first real issue...
Yeah, that stinks..

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About a week ago Jason told me to look at a 1998 KTM 380 air box I had in inventory.
I pulled it out thinking no way is that going to be even close...
Guess what...

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Another builder, Jan Pettersson, gave me this info...
Nice, I think I going more straight, The shock is more at right side in frame and can be avoided more easy, intakeboot from 1986-kx500 and airboot from ktm 300 twostroke give less angle.

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With just a little fudging it went in.
A few minor issues and it works like a champ..
Nice job Jason...