Honda Odyssey FL250 Makeover

[bighead]

No rest for the wicked. This Ody will be a graduation gift for my little brother. I got 30 days to finish it. It will get rebuilt roll cage like stock. I will take the Ody all apart and scuff the original black paint and rattle can. No time for POR15 prep and all that. Make it all look pretty with new red fenders.

The fenders are $250 but most the parts on this one are good. It runs very good but front end has heavy damage. This will get fixed for I have all the parts. Frame will have to be fixed as well for the main j-arm bar is bent good. I may just change out the frame for I have a few of them. I decide that when I get it stripped. It will also get nerf bars and side cages like my other Ody's

Notice how tweaked this cage was. Also notice the steering column is tweaked as well. It took a super hard hit to move that colunm like that. Also to krinkle the cage like that. This Ody does run well and has 148lbs compression. Starts right up. The good thing about the frame is it's easy to fix. Just fix that main front bar and your done. Not sure about the column yet. This is the first I seen this. I am sure it's easy as well.

The 5th pic shows a fast way to see if your Ody's frame is bent. The rubber bumper stopper should contact the middle of the stop. Notice how mine is way off target?

Crazy as it sounds I seeing signs of low hours. My guess it was a fair Ody until the last owner got it. Rode it hard and put it away wet. Does not take long to look like this.

Here what I am starting with and the work I did today.

[bighead]

It's going to get a cage, front bumper and nerfbars like the Ody on the left. It will be close to the same but will mix it up a slightly different style.

[B man]

I like the No cage look alot.

[rcarteraz07]

I envy you and your brother! That's pretty awesome of you though. Good luck with this rebuild!

[bighead]

Went back out after dinner and did some more work. The bent column had wondering. Looks like the column can steering shaft is bent. The frame the column bolts to is fine.

Front end left side has parts replace with early model parts. It also has the early model shock on that side. Original parts most of been toast after the crash.

Also the pipe has been welded for some reason. In the pics thats a bracket that bolts to the frame and the pipe. For some reason they welded the bracket to the pipe. Hack weld at that as well. Also no nuts on the tierod end. Lots of sand pack into all the corners and hiding spots.

The good is that there is no rust. All the bolts are comming out easy without snapping. Wire harnest is uncut and okay. Cables are both good. Both brakes are good. Axle still shows original gold color. Tires are good with okay aluminum wheels. Runs killer. No rust in tank. Although the frame is bent both j-arms and spindles are fine. Real axle bearing are tight. Reduction unit is tight with no leaks. Newer belt. This Ody did come with the tail light but not in pics.

The bad and needing replaced.

Steering column and shaft,tierods,pipe&bracket,and one shock. Seat pan is rusted out. I am out of seat pans so I will fix this one by welding or revit some sheet metal.

What will it cost me? Have all parts but the shock.

Shock $35
Lots of paint $60
POR15 Marine Clean $13 (Only degreasser I will use)
Sandblast foot tub for good paint tooth $30
Steel for bumper and cage $40 (have some steel may be less)
Fenders $250

I traded a ATC70 I had $250 cash or so into the ATC70. But it was worth about $600. I would rather have a $250 Ody than a $600 ATC70. The ATC70 needed the over priced pull starter at $200 cheap. Plus it was a no cash trade. I knew it was beat up but I could see the light as well.

All said and done I will have $700 into this ody and it will look nice. Fenders will kill your budget but they are a most IMO. If it had good fenders I could do the build for about $450 total to me and $165 for the build. Keep in mind lots of parts on this ody were good. Like bearings and cables and brakes disc/pads. Most the time this is not the case. But thos parts are cheap at about $10 each. Even the cables. It will be worth $1100 to $1300 in my area. More if I did a full restore.

Gas tank will not be painted. Just cleaned up. Why paint the tank when gas will just kill rattle can paint. It would look like crapo after a few weeks spilling gas on it. Better off just cleaning original paint the best you can in this case.

Last pic show a parts bike I have. I may use the cage if I can clean it up. I will use the hoop though for sure. It would save me lots of fab time and steel cost. The cage is in good condition but huge blob welds were it cracked before.

[bighead]

Damage report

Bent frame
bent tierod
One bent wheel
Bent bumper mount on frame
Hole busted thru transmission/reduction unit
Pipe has weld job that turn it into near scrap.
Bent steering shaft at pitman arm
Bent steering column

If I did not have a small junk yard of parts this deal would have went sour fast. This ody took a hard hit or fell out of a truck. The frame can be fix if a guy needed to. I have extra frames in good condition. I have only the early model frames though. The only difference is the front bumper bracket the bumper bolts to. It will be faster for me to cut the bracket of this bent frame and weld in onto the good early model frame. Than to try to fix this frame.

The good news is I found some fenders I forgot I had. So now all I need to find is one used red front fender. About $50 on Ebay.

This pic show the pipe. Not sure what this person was thinking. It is what it is I guess. It's not junk but it goes to the back of my parts pile for sure. Some day a person will need this pip.



This pic shows the hole in the trans I found. After I got engine out I saw some silicon sealer on the tranny. I tore off a pop can and sealer patch fix. It's in both cases so this would have been a $75 replace if I did not have another one. Good clutch and good parts though.



Here you see the patch I dug off. Pop can and some sealer.



Here you see how far the frame is bent. The rubber stopper should be in the middle of the stop. It does not look that bad in the pics. But it's about 1/2" off. By the time this gets out to the wheels it's all out of wack. Also notice the damage on the frame. When it took the hit it rammed that stop right into the frame making that mark like that. Also breaking the spot welds for I see rust. I think it's broke anyway. That stop plate should be a little over 1/2" away fromthe frame. If you are ever checking out an ody this is the first plce you look. With all the plastic and foot tub you cannot see the from main bar is bent. Check this spot for condition of frame.



One bent tierod and early and late model shock. Must of busted the shock in the hit. So they replaced it with early model one.



Bent steering shaft pitman arm. Thats some thick steel to baby.



These next pics shows the bent front main bar.







Twisted lower bumper mounting bracket.



Stress cracks/pulling on spot welds.




As you can see the frame can be fixed. But less work to swap them out. Cutting and welding two brackets is faster than fighting with this frame.

I found the wheel I will need. $60 shipped. So add $60 to the total but take away $200 for the fenders I know longer need. Okay trade off I guess.

[bighead]

Just random pics during the tear down. Also I will not be adding nerfbars. Just side cages. My old man does not want them on there for to much room in the truck when they go camping. I guess they can slide them out but he does not want to deal with it. I will make some sick side cage though. It will be much safer than open.

[bighead]

Started tearing done the parts bike for I need some parts off it. Don't have room to store it and needed it out of my driveway.

First pic shows the tool I made to fix the frames. It's made from and old J-arm so it fits over the bar perfect. This stops the bar from ovaling when ranking on it. I stick and old 350x axle into the end of the bar for more leverage. If you make one of these it has to be from thick thick steel. Or make a better design. I got some ideas to stiffing this one up and both pipes are like 1/4 thick. The old J-arm pipe is thick as you can see in the pics. The bar on the Ody os thibk like this too. You need heavy duty stuff to bend it without heat.

Rest of the pics are just random pics of tonight work. And my growing parts piles. I will be using this frame. It's it great condition.

[bighead]

I got both Odys taken apart. I had to put the cage and foot tub back on to make my bumper and side cages.



I am using an early model frame so I had to cut some brackets off the old frame and weld onto this one. On the early models the bumper bolter to the shock mount. Honda changed this in the later (red) models. If the bumper takes a good hit it will bend the shock mount. In this pic you can see the early style mount on the shock tower. You can also see the bracket I cut off the old frame and ready to be welded. Now if the bumper takes a hit it will fold/flex this bracket.



For the bar that runs out to the front bumper I used both sides from the original Ody bumper. Less work and all the holes and bracket is already welded.









I have this main bumper bar you see in the pics. And another a little smaller. Not sure what I am going to do yet. Just going to drink a few cold ones and see what I come up with. (Love this part) Still need to make the bars that come from under the ody.






Well do the side cages tomorrow. Then it's ready for the mass degreasing and cleaning.

[raffa83fl250]

That odyssey had a lot of front end damage, looks like it will be alright with all your spare parts, just wondering how the nerf bars are going to look on this one. Are they permanently attached? Or can they be removed?

[bighead]

I changed plans on the bars. My old man does not want them on there for they take up to much room in the truck he claims. It will get just the side cages.

[EvoDre]

nice build, looks like its coming along great!

[the-cyborg]

bighead do you know someone with a TIG welder?
It wouldn't take too much to TIG that tranny case in both sides then grind it down and blend it in you'll never know it was even there.
I TIG stuff like that all the time, because I'm cheap, pragmatic, and have more time than money.

Of course you'd have to split the case, degrease it really well first, yes it's a little work but would be worth the effort to me.

[bighead]

Originally Posted by the-cyborg

bighead do you know someone with a TIG welder?
It wouldn't take too much to TIG that tranny case in both sides then grind it down and blend it in you'll never know it was even there.
I TIG stuff like that all the time, because I'm cheap, pragmatic, and have more time than money.

Of course you'd have to split the case, degrease it really well first, yes it's a little work but would be worth the effort to me.

I do not have a tig or know anyone with one really. I will save the cases though for I know it can be fixed. Right now I have a few of these trans so back to the parts pile it goes. Or donate to the next member that needs one.

[bighead]

I got the bumper done today. I used the parts from an old fl250 bumper I had. By using the bumper I was able to make it without any bending.

Still not done. Going to add some to it.

I need a red front right fender. There was a member on this site who had one but I cannot remember who? If it's you let me know. Need one asap will pay near top $ or trade.

Some pics

[bighead]

I got the side cages done today. I also added two bars behind the driver head. I will put foam padding on those three bars. Also padding on the side cages and the three bars going down on the side cages. This will protect the drivers head from behind and the sides. Hard to see what I am doing but trying to protect the whole head area with padding.

All fab work is done besides the weld up. Time to start paint prep for next weekend.

Some pics

Edit: I am adding a bar on the roof to the hoop like the fl350's have. Helps keep the top roll bar from crushing in.

[landuse]

Looking good. Keep it up

[rcarteraz07]

Looks pretty good so far! Can't wait to see the finished product!

[bighead]

Another Ody gone crazy. The mods you can do to the fl250 is endless. Once you think you seen it all you always see more.

I like it but not sure about that huge tank on the side. And the engine is way hi in the chassis. (not good) Also the half roll bar in the back? (not good)

http://sacramento.craigslist.org/mcy/2998090347.html

http://www.youtube.com/watch?v=Z0HHK...ature=youtu.be

[bighead]

Been a few days but still chugging along. Got all the parts I am going to use ready. Also today got most cage to bare metal. It should be in paint by Sunday if all goes well. All original colors. This frame was already stripped at one time. So clean up was really fast. Most the time lots of rust under the frame. I also got all the smaller parts soaked and cleaned in degreaser.

Even though it is a makeover and not a full restore. It will still look nice and have good used parts. Just the paint wil be rattle cans so will not hold up the best. It will look pretty though.

My brother has about 5 akers to ride on. So it will be well used anyway. If he takes care of it we can always trick it out later.