DOCWOB – Husqvarna CR500 re-build part 1 – Mike Brown Bike prep

Husqvarna CR500 2 stroke build, VMXdN Foxhill 2024 builds, DocWob Titanium for Factory MXGP teams and titanium foot pegs in the R&D workshop! There is plenty going on here at DocWob HQ.

First up we have a Husqvarna CR500 I am building but this one is it a little bit different, it’s for me, one for my collection. I had one back in the day, and at the time it was advance with its air-cooled tank and disc brakes. Find out why these wheels drove me insane – bearing in mind I love building wheels and why the build is testing my patience.

DocWob titanium is busier than ever. With factory teams requests coming in and shipments going out daily its full throttle. Last year our bolts featured on the machines of the Top 10 MX2 bikes and if you include our tools in the mix, we also featured on the Top 10 MXGP bikes.

In the R&D workshop we are working on manufacturing titanium foot pegs and before the summer gets ridiculous busy (more on that in a future episode) we have made a start on the first on the VMXdN Foxhill bike builds.

What are we building? Check out the episode.

If there is anything you want to see or ask – drop it in the comments.

Don’t forget to like and subscribe.

You can find all our titanium parts and everything we make for the factory teams in our eBay store.

DocWob
Follow Us on Facebook
Doc Wob Imports | Facebook

Follow Us on Instagram DocWob Imports | Motocross (@docwobimports) • Instagram photos and videos

Shop DocWob Imports and DocWob Titanium
docwob | eBay Stores

Special thanks to EKVisualPro
EK Visual (@ekvisualpro) • Instagram photos and videos

VMXdN Foxhill
Buy Tickets to VMXdN Foxhill 2024
https://www.eventbrite.co.uk/e/vmxdn-foxhill-2024-tickets-753835631667

Follow Us on Facebook
(2) VMXDN Foxhill | Swindon | Facebook

Follow Us on Instagram
VMXdN Foxhill (@vmxdnfoxhill) • Instagram photos and videos

Visit the VMXdN Foxhill website

VMXDN Foxhills

You can see through [Applause] The oh Yeah oh yeah Rob bit from wob this is episode 22 or something I think um in this one I’m going to show you a few bits and pieces we got going on first off we got a couple of really nice if you like them husana this is a CR 585 that’s an XC

585 um I used to have one in 85 actually back in the day they were quite a good Tool uh cuz everything else was a bit as well so they were you know single shot Disc break water cold ticked all the boxes more so than Suzuki or

Yamaha or anybody else at the time really it was as good as anything um I still think they look cool I want one for my collection so I bought this one 5 years ago took it apart now we got a bit of time on our hands we can put it back

Together the other one I bought as a donor turns out I don’t need any of the parts cuz there’s nothing wrong with this one so now that’s just having its ass wiped as we say in the trade and uh we we’ll get that one for sale this one ain’t for

Sale so 85 husky CR500 um quite not ahead of its time but was of the time there was a proper thing um the they really not very easy to rebuild though um all the nuts and bolts are just stainless Allen Keys 13 mil heads 10 mil heads nylon lock nuts all that but

I haven’t got much of it in stock so we have to buy it all in cuz most of the stuff we got is all Japanese or KTM fitment nothing of that fits this bike at all so first things first frame off to the welders Swedish quality no welding no nothing everything’s meant

Just powder coat thing white cheap jeap uh commissioned a tank from xfund to be made I think you can buy those now we can definitely get you one if you want one uh it seems to fit seems to be okay but I’m not going to powder coat it

Until the pipe comes from jsv because I’d hate for it to hit the pipe and me have to modify something after it’s been powder coated so that’ll be the last thing to be done airbox massive air filter to give you the airbox volume which is really cool um old school car

Big round slide on it nothing too fancy but the bottom line is it’s a single cylinder 5002 stroke no power valves just ridiculously f fast left hand Kickstart which was never much fun to start but they’re just big tall numb thing I’ll never ride it heav

Forbid I’ll even start the thing up but it looks cool so it’s going in my collection just so I can remember my time on one of These so one of the biggest ball legs on this was actually the wheels the rims on these Nordisk rims they cra that first husky everything’s Mega quality the rims maybe not so much so they all crack so we’ve got to weld the rim redress it all up reiz it then new

Spokes powder coat the herb the whole Chang problem is with the spokes is they have a 90° turn on them which is a real ball Lake and they go like this direction so you have to build the whole wheel cable tie the spokes in place with the three

Crossover then place the rim on and build it up that was hard work the front looks easy not so much because the spokes I bought were like two different sizes turns out you need three different sizes so Talon hooked me up they I ended up pulling my hair out I tried it for

Hours about 4 hours I was about to throw it through the window but Talon hooked me up they laced it up it’s all true now so the wheels are good new tires on it new brake shoes new sprockets everything good to go brand new ready to Go got the noise they’re going to make is unbelievable so the Husky was ahead of its time really because it was the first bike to have the air fo or accessible without taking the seat off and dropping crap in there also the size of it because they have to get the really

Essential airbox volume which is the the volume between the inside of the filter and the back of the carb slide which incidentally was all these people who make all these AF bikes go wrong because it’s so close massive air F makes it up so what you do is basically the little

Screw on the front of there two clips side of the airbox comes off and you got your massive filter so for this build I commissioned aluminium tank to be made I think you can buy them now but I got the Ali tank made because the white on the standard

Tanks just gets Mankey and anybody who’s got a nice one they want thousands of pounds I ain’t paying so we got an Aly tank made there’s a few more little mods to make cuz the moment it hits the head we’ll modify that a little bit um we have to modify the rad

Shrouds cuz on the production one they go into a slot so we’ll put some rubber grommets in there it should all be good I won’t powder coat it till the last last second because I want to make sure when the new jsv pipe comes nothing hits nothing’s touching before we get it

Powder coated and lastly have some stickers on it yes a youit nice kid though really nice guy really enjoyed his company ATX so font pipe’s going to be Handmade by jsv silencer I managed to save the standard one the only problem was the end was a bit chewed up so I did panel

Beat the end a little bit I cut 15 mil off the end and redrilled some new screws so it looks nice and new obviously I have to shorten the tube on the inside a little bit um these bikes came standard with oens shocks being Swedish um this thing’s been a part long

To be honest I think it’s a bit short I don’t know why it’s short cuz all the same bits went back together so I think a bit more investigation in that but powerder coat the frame PL it it all up there’s a new knob on the way from there Forks

Are um husana own make um really basic but they work really really well uh this was the first Disc break so quite Advanced for its time bit grabby if I remember rightly bet the back breake don’t work worth a Engineers over where’s my coffee anyway

I thought you would be com in no so on these it’s very weird the seat attaches to the bike with a rear fender attaches to the seat this is the wrong seat cover so that’s going to come off uh mxa will do me the the right seat cover foam’s

Still good to go um the hardest bit to find on these is the side panels so we’ve got a couple of sets to pick from we’re just going to have to make the best we got because the aftermarket ones are junk so we’re going to have

To just clean up I’ll speak to Keith we see if he can clean up the standard ones for me give him a Polish um cuz this thing’s going to go in my office so that’s enough with these Huskies for now I got to tell you I can

Only work on them for a couple hours a day they do my nothing so I’m more motivated 2 hours I’m done I’ve got to go and work on some sensible so let’s go over to the uh blue Workshop I show some of the R&D stuff we’re working on So just to give you a little insight uh Yamaha had a bit of a switch up this year so the kameha team which were the MX2 team have now gone to run the mxgp team which is the 450s um we happen to be filming on the day but these were

Ready to go so this is this is their order for a year um today we’ve shipped KTM Factory racing which is also gas gas Factory and husana nestan and um because we sign a non-disclosure agreement I can’t show you what they’ve had but this is the amaha stuff so rest assured the

KTM Husky gas gas order was big so keep an eye out for our guys luckily you know we won both World Championships last year with titanium top 10 in MX2 top 10 in mx1 if you count the tools um we’re pretty prolific at the Grand Prix scene

Most guys are using our stuff there now so uh onwards and Upwards okay also we’re working on a new Billet titanium foot Peg um first off is going to be for the Hondas so this is a HRC Peg um which was fit to the Loo bike problem is with HRC pegs they use the HRC hanger so we had to redesign the peg

To take the production Honda hanger so we can keep the price down we do have tanium hangers for these so basically this is a 3D a plastic 3D printed version which is that portion of the HRC Peg with the production Mount so you can

See it goes on the bike um so we can make sure fitment angles all that stuff so this just goes on there sits right looks good operates properly um wouldn’t want to stand on it though but this way we can approve it before it gets made so this is we’re trying to get

Ahead of ourselves for 24 The Summer’s going to be ever so busy can’t really tell you why yet but it’s going to be a little bit off the hook so I’m trying to get the bikes built this is um a 252 Stoke we’re building 2002 we’re building for Mike Brown he is now

Contracted to Triumph so we have to build the bike in accordance with this contract so bike’s being built black and it won’t have any other brand logos on so start off frame gets stripped we weld the logs on for the skid plate new steering stops steering damper check

Everything out we do Guss it a little bit around the top shock mount then it gets powder coated and you will also see that I have removed the powder coat from all the mounts all the electrics so you get a Good Earth and the thing won rattle itself to bits by bolting through

Soft powder coat so frames ready to go first week in January the target is to have this bike on display at the tford international bike show second week in February fingers crossed we should get there so for this bike we’re using our customade aluminium tanks with the

Airbox vent holes which come out into the airbox provide nice cool clean air flush fit gas cap and um the special vent so it doesn’t splash down the front fender uh the steel frame tanks are different to the aluminium frame tanks they’re actually wider here on the steel frame so you

Have some custom made for the O2 to4 the 05 onas won’t fit so that is basically going to be on there about there so it’s going to look pretty cool uh this one’s going to have uh KYB forks with our buet feet ol shock and the moment we’re Midway through the

Modifications on the swing arm so the swing arm’s Midway through being done um first job trip all the metal bits steel bits off get the swing arm dipped to get all the anodizing off replate these plates put it back together at the moment there’s no bearings no nothing

It’s as bare as it can get uh we cut a tube to replicate the rear wheel tighten it all up so when it gets welded it doesn’t warp or distort um engineer boy makes a new rear brake carrier bracket we’ve cut the old one off we’re running

The more modern wiser F rear brake 245 rear disc this will get welded in place with the wheel in its furthest forward position tacked and the wheel in the rearward position tacked so we know we can go through the uh range of chain tension without it binding up so that

Means we can run a wiser left wheel big brake and then I’ll do the fluff and buff on the swing on which I will actually show you what we do on the next episode so that’s it for another episode OFW TV we’re back on it flat out we got

So much stuff to show you um any questions shoot us a message leave a comment and we will get back to you anything you want to see like And subscribe that really does help and um thanks for watching that’s all I can say thank you