DOCWOB – We build 7 Yamaha 250 2 Strokes! Well, almost…

We are balls deep into the bike builds for VMXdN Foxhill and this year we have Farleigh Castle Vets MX too.

Every year I say we are not building as many bikes and every year in May we have more bike builds on the go than originally planned!

These two strokes builds take me back to my days on the spanners and it all starts by taking her down to the bare frame and cleaning everything up ready to re-build for race weekend.

It’s all about the YZ’s this year, A fresh new look for Ryan Villopoto’s and Zach Osborne’s old bikes and complete new builds for Andrew Short and Alessio Chiodi who are both competing in the VMXdN Team Race.

We have a 93 YZ250 Chesterfield ‘Donny Schmit’ style on the go, and we might have to build a couple more Yamahas as we still have some big names circling – you will have to watch the episode to find out who.

I let you in on why we don’t powder coat the tanks until the last minute and my FaceBook marketplace mishap – we’ve all had one!

Don’t forget to get your tickets for VMXdN Foxhill 2024 – https://www.vmxdnfoxhill.com/buy-tickets

Whilst I crack on with these builds don’t forget to hit like and subscribe – cheers

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

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VMXDN Foxhills

oh yeah welcome tow TV uh this episode we are balls deep and getting ready for vmxdn Fox Hill Farley all those events um it’s a lot of work and every year I say I won’t do it but every year we do it again so this year we’re going to re reuse a couple of the amaha that we ran before uh the Osborne one and the voto bike so every year we have to have a different aesthetic if you like because people just bored seeing the same things over and over again how do we give it oh here’s this year’s builds if they look the same as last year’s builds no good so we’ve gone for black uh we will show you the graphics in another episode so we’ve gone for black frame black tank gold rims and then the rest of the bike is just going to have a regular week in week out rebuild this is what we used to do as a factory mechanic every week bare frame the bike um on the Sunday usually after the race Supercross Monday after the outdoor Nationals or grand pris so you basically bare frame then you rebuild the motor so that’ll have a new piston new clutch uh we’ll measure up the big end and make sure it’s all good to go suspension will be serviced Grease the linkage Grease the steering bearings and basically clean the carb just clean it all up put it back together [Music] [Music] so we lay everything out um not because we don’t know where it all goes cuz we could build it out of a bucket if we wanted to but basically a lot of the job in between races is inspection making sure that nothing’s rubbing nothing’s cracked nothing’s doing anything it shouldn’t do so yeah we wash the bikes but then uh we take them apart wash them again properly um so we start off Lay It All Out see where you’re at all the nuts and bolts get laid out we do put all the th nuts and bolts in a tumbler and that polishes them up overnight which looks great um so we’ll just service everything up really make sure there’s no cracks there’s no nothing’s breaking new oil in the forks new oil in the shock obviously all new fluids throughout uh the frame the first job is to um we that was a blue frame last year so now we just paint stripper it cuz it’s too much if it gets blasted and whatever so we just paint stripper it um get it back to Bare Metal have a good look around all the joints all the bits and pieces we’ve welded on then it goes for powder coat we do the same we always do grind the powder coat off all the mounts chase the threads through make sure they’re clean and then just start putting stuff back together just start cleaning up cleaning up like brand new um nothing’s too beat up but just a little bit of green Scotch Bri by hand in the parts washer cuz if you want it to look like a ‘ 90s bike that’s how you have to do it we didn’t have Vapor blasters back in the ‘ 90s I wait for someone to save I want to tell you something new you drove a CL into a wall I drive away into the night and I contate for big part of the bikes always the wheels um for this color scheme we’re going to go gold rim so Talon hook for sent us up four sets of gold rims um re I rebuilt them the spokes were good to go we didn’t have to cut them out um they only done one race really so couple of practice sessions so I rebuilt the wheels new bearings um new set of Mitchell and Star Cross Sixers um these are built with tubes because uh we’re still two months out from the race and we don’t know what we don’t know what the weather’s going to do and also we will have brand new tires delivered like the week before the race so they’re as new as they can be and also we’ll run Moes and you don’t want to put the Moes in too early cuz it will they’ll shrink so for now on the builds they got tubes in um we will run them with Moes with a tire that is befitting the conditions but for now they just got Star Cross sixes in just to get them running and rolling around and getting built so we’re on with the builds uh we’re hoping to have we’re hoping to have these bikes ready to go graphics on them covers over and we’ll start using them for a bit of promo Engineers over where’s my coffee anyway I thought you want be come in no so this is a new build this is the 94 Chesterfield y said 250 um the guy’s buying this and he’s racing out at Fox Hill so we’ve got to make sure that she’s done in plenty of time we’re not a Million Miles Away now we’ll have the motor built next week I’m hoping uh the clamps are all in the front end Forks that’s always a biggie because making that more modern stuff these older bikes is always a mission uh wheels are built um the shocks are all the way at johon o White’s case getting serviced up cuz I haven’t got the tools or the noow to do oin so uh easy man for them so like I say linkage is done frames done uh Plastics are all here Graphics are all here we’re pretty much cracking on with these now I know they don’t look it um tanks will get powder coated after everything else is built just to make sure that nothing needs moving denting Rec cutting we we we D they should be fine they always are but it won’t take 2 minutes to power to C it black when it’s done so this one is a 1993 Chesterfield y 250 Donny Schmidt bike um big job again conventional Forks gold up a tubes spillet clamps hard work they are but they do look great I don’t if i’ want to use them I suppose they work good they work good enough they just look cool cuz that’s what they’re supposed to have in you know we race them with upside downs but the conventionals is the way to go for the display bike this one is supposed to be going to California to go on display but we’ll wait and see whether that actually happens it’s got the buet linkage and the hubs of Wheels been done so the motors will be built these are not priority this one’s not priority if it gets built for Fox Hills to be on display Happy Days uh if it’s there we’ll get Damon Bradshaw to do a parade lap on it if it’s not it’s not so um we’ve got a few more things in the pipeline yet we might have to build one more yam race bike yet we don’t know [Music] so we’re into the new builds we got a couple of new Builds on the go uh this one’s for alesio chot this one’s for Andrew short so the Chote bikes just waiting on the cylinder and the shop to come back from uh case so the cylinders come back yesterday from pro circuit so I’ll show you those um this is ready to go in the in the color scheme we’re going to be running um I’ll show you the graphics next episode these things are trick these things are really cool so these two cylinders just come back from pro circuit Mitch pton handed the cylinders he was on the phone to me midnight asking me a couple of questions about bits and pieces um so I know he’s done them they will be really really good um they’ll have to run on vpc1 12 from now onwards cuz they’re going to be with the compression do detonate to otherwise and you see this little spacer we have to run the spacer underneath the spark plug so this plug sits in the right position so the head’s been done to run on C12 cylinder’s been done Mitch will do two different jobs on cylinders you’ll do a race team job which is just a bit that needs doing or you’ll do a customer job which is he cleans up all the inside of the port so when the customer gets the cylinder back they’re like oh this looks great if you actually see a race team cylinder that’s been done it doesn’t look that much different don’t touch much of it they only do what they need to do so uh these have been done by the man himself uh we’ll match them with the pipes silencers and then we’ll go out we got pretty good ideas on jetting settings we’ve done them for a couple of years so we know close to what we’re going to do obviously the weather is going to change by then but if we can get these two cylinders on these bikes this week uh we’re really going to be cracking on uh we want these bikes done uh two months before the event so we can use them for promotion we can go and try them we can test them we can run them in we can get Steven Clark to come put some time on them hopefully [Music] and we might have another one we’re yet to build um we got to figure out what dam and Bradshaw is going to ride for parade lap um we’re yet to hear whether vot is going to race he wants to race the um normal super Evo class so we’ll see whether he wants in there um we have got word that g poin wants to come and if so has to be on Yamaha so that could be a last a last minute build and giod has gone for the VM xdn class so he’s in the team Race with David guer and another Italian team headed by David philippart so we got a lot of Italians a lot of good Italians coming world champions um he’s chasing the competition alao he wants to go out there and get in the thick of it so we got to build him a good bike and I think we’ve uh tick that box so far can must have wake me up in a minute so this is another said 250 uh it’s a new build for Andrew short this year he’s a new guy on the American team for vmx on foxville um we’re a lot further on with this than it looks I know um the hubs and the fork tubes coming back from s Max OE Benton’s got those we got to pick those up tonight so we can have wheels in this tomorrow um shock again is off being service by jonno um cylinders here now from PC so we can put the studs in the cylinder put the cylinder on um Fork tubes again OE bent and Sarah Max so we can build the forks with a Billet fee uh this thing is a lot more on than it looks so no dramas two weeks we should be firing this thing up I forgot to mention the jet ski plug cap how cool is that on these we had these in the nights these were really cool these are actually a Kawasaki jet ski plug cap so if you want it to be waterproof you can’t be a jet ski one so this part goes the plug holds that on the plug bolts down through it then the cap goes on and you want a cable tie around it so it’s not coming off little bit Overkill but we did it back in the back in the day and that’s what we’re doing now so anyway so that’s six bikes in here all on build this workshop’s full um we do have one more let me show you [Applause] [Music] [Music] [Music] so this one’s the seventh YZ 250 we’re building for this year’s event um this one is actually an 01 YZ 250 we’re building for a guy called Leon caps super super nice guy uh he’s Ryan V’s man friend and he he’s the reason why Ryan comes so we built him an RM last year and he hurt his shoulder so we sold it and then he’s looking for a bike for this year Fox El Farley so uh I went through the cupboards and I realized I had this 01 250 that we’ve been robbing bits off um bit of a weird story with this one I felt a bit of an idiot to become honest I bought it on Facebook Marketplace which is always a bit sketchy and pictures it said it was advertised as an1 why is there 250 but I looked at it and I’m like that’s too so I’m like he don’t know what he’s got this bloke so I bought it sent down to go and pick it up he bought it back turns out it’s an 01 with all O2 tank O2 Plastics cable tied to it and self tappers and you’re like oh so it just got took apart and shoved in a box and we’ve robbed a couple of bits off it since then so now speaking to Leon we’re going to build this 01 up for him so Le is up on its Wheels it’s Bill it’s a physical bike it’s not um just a bag of bits anymore so we done all right we found some kit forks for it so it have a clamps kit Forks we’ve already rebuilt the wheels with new Talon black rims Sunstar sprockets new discs they’ll have um sub frames been repaired where it got self tappers put in it the frames off to be powder coated silver cuz this one’s actually going to be cuz it’s a 96 to1 shape we’ve got all those different bikes to pick from so we’ve gone for Talon volen 98 look which is blue with silver raldi bike beautiful bike so the frames off to be done silver and then the motor is ready to go so this will be at foxille and Farley um it’s not going to be as expensive as build as the other ones um but it’ll be right so it’ll be good so the swing arm on this 01 is going to be it’s a lot of work um when we bought it it was powder coated black which means yeah you can get the powder cut off but it means the whole thing’s been blasted like heavy you so of bring the Extrusion part back to be shiny looking we do re blast the cast section cuz that’s how it’s supposed to look but we hand polish this but these swing arms they’re 20 some years old so there’s always um tracks where the hoses have been and this here is filled in where the front chain slipper goes over um and it just gets dirt underneath it oh upside down just gets dirt underneath it and chafes around so we get Martin our welder to fill it in for the weld we grind it back and re blast it we rewind it here um somebody has polished this swing arm with an inch of its life so there’s hardly any weld left so we go over the welds again there’s a big dent there which has now been filled in um little scratch there which has been filled so it needs to be ground and then polished uh it’s probably a day’s work to get the swing arm back to useful condition so that’s it for this episode um don’t forget to like And subscribe it does help um whever Danny puts those things uh so there’s seven bikes on build they’re all going to be ready for the end of August this is going to be a bit of a challenge but we’ll get there we’ll get there I’m confident we should be ready on the bikes in the other Workshop within a month then this might take a bit longer but it doesn’t matter as long as it’s done so um Andy Willet wi is helping us with this one cuz he good friends with Leon and so he’s um he’s doing a lot of the work on this one for us [Music]