.38 Special - Project Build

[StuntBikeJake]

Picked up RustyStunts 03 636 over the weekend. Beyond sick of my 08 zx6r. So I figured I would use my flossy minty parts off the 08 and upgrade the 03.

Parts transferring from the 03 to the 08:

Forks
Wheels
Fender
Rotors
Calipers
Triples
Clip Ons
RSC
Magura hb master
Brembo front master
Controls
Swingarm
Sprockets
Chain
HB Setup
Radiator
Shock ( dunno if it transfers or not)
Battery


Pic of the donor bike



Pic of the 03 when I got it back home after driving 22 hours to pick it up



What the 03 needs:

New Clutch
New Rad Cap
New Thermostat
Coolant System flush
Rear reservoir
Cam Chain Adjustment

Plan:
Plan to just swap the essentials over to the 03 til the end of season and put in some work. Gonna worry about making her pretty in the winter months, for now its all about getting as much ride time before the cold sets in. Its gonna be extremely ugly until then. Gonna need to pick up a halloween edition RSC for this bike as well.

Let the tear down begin..







No leaky valve cover gasket, im honestly surprised.. my 08 even leaks...







Removed the zip tied on radiator



This is where I finished for the evening.



As of yet I have not found anything crazy or shocking or unexpected. Frame is solid, no cracks as far as I can see, the motor is solid no leaks, honestly its cleaner than my 08...

Hopefully tomorrow I will get the 08 front end swapped over to the 03 and start getting the rear suspension removed and ready to swap out.

[navajowalks]

Jake do the cutting board support before you put your tank back on...

[loogie]

Originally Posted by navajowalks

Jake do the cutting board support before you put your tank back on...

Good call..Theres actually a better/EZier way tho,just go to ace hardware and get 4 rubber grommets,2 small,2 large and put 2 in the middle of tank on both sides where it meets frame rails,then 2 on each side on the back corners of tank,right on top of the top subframe mount,and wa-lah,that shits solid with lil bit flex/cush but no twisted tank mounts

[StuntBikeJake]

Planned on resolving that before the tank went back.on.

[Beto]

about time! Looking good so far, that 636 looked like a good deal

[Austin913]

welcome to the darkside. props on the new ride.

[StuntBikeJake]

Didnt make much progress today.. had a rough day today. Went to visit my grandmother and see passed upon my arrival.. so I tried to get to the garage to keep my hands and mind busy.. I wasnt that successful...





For future reference if anyone needs to know the size of the allen for the swingarm bolt on an 03-04 it is 17mm, I had to go buy one since I did not have one that big...


Started stripping down the donor bike as well... Hope to have at least the rear suspension on the 03 tomorrow

[matthunter1448]

jake sorry to hear bout ur grandmother , if u need any help hit me up i'll be glad to come help the transformation!

[da Liks]

i'm happy for you man! your gonna kick ass on this thing!

[da Liks]

btw didnt read the 2nd page before i posted! my condolances.. sorry to hear that buddy!