Honda Odyssey FL250 Rebuild

[bighead]

u should make it look like the yellow ody
i rekon that look is mean and fast

I would but I am not to good bending pipe on my HF bender. We are going for the stock cage look for ease. fabricated bumper though. Also going to add nerf bars and side cage like the sled Ody.

As soon as I get this one done. I got two more for full restore before a August camping trip. If I tried to bend up pipe for a full frame it would take me a year. Not to mention a few miles of pipe.

 

[bighead]

Hello Friends, Father in law and I spent about 8 hours working on the cage. Not as easy and it should be for everything was bent. Also the spare frame was from 1978. So I hade to weld on the bumper brackets.

Got the basic cage done. Still going to add some to it. As well a little side bars on the bumper hangs. Starting to look like an Ody again. Added new down bars that got rid of all the bends and dents. The nerf bars my father in law came up with. We will be adding another bar going to the main hoop for beef it up.

Anyway as always here is some pics.

 

[anderkart]

Looking good man

 

[bighead]

Thanks Anderkart,

I got the roll cage all done today. Also finished the side cage and front bumper. Welded on some tabs for the battery box mount. My fathger in law will prep for paint. I will start working on rebuilding parts. All new bearing and seals as well. I am really digging the Goki electric start kit I have for the FL250. Going to be nice to have.

Also need to start work on a new seat pan. The original was all rusted. LOL

Some more pics of todays work.

 

[bighead]

Engine soup anyone? Got to take the electric start off one. The CDI off the other.

One engine a new. One engine runs but bad seals. And one engine has bad piston. Going to rob all the goodies. And then rebuild another engine with the parts. Also a box of parts getting ready for paint.

Some pics

 

[Bluethunder3320]

quite the shop you have.

i still wonder how its possible to get so much stuff like you have!

 

[bighead]

quite the shop you have.

i still wonder how its possible to get so much stuff like you have!

Blue I have a feeling when your 42 you will have more stuff than me. #1 rule is to collect any and all tools. I am a garage sale freak. When you get a job you need to go garage selling alot. You will have mega tools for cheap. Just pack rat everything. On average I will come home with a shoe box of tools every weekend yard selling. Maybe 20$ spent. Also there is so so more many tools I need. It's never ending really. Amagine a shop with everything?

Also pack rat every nut a bolt you can buy for cheap. I buy coffee cans of bolts all the time.Over time you will have a bolt bin like this.

Check this out.

 

[bighead]

My seat pan was rusted really bad. I was able to get my hands on a better pan but still some rust holes. To fix up the seat pan I added a peace a stainless to the bottom. Much stronger now and should be able to take some good blows now. On an Ody the bottom seat pan acts like a skid plate.

Also just doing a bunch of cleaning for paint.

Tires anyone?

 

[redsox985]

Now, BigHead, can you actually find anything specific in those nuts and bolts? That's a ton of stuff. I believe I asked before. Would you be willing to leave me 1% of your tool collection in your will?

 

[bighead]

Nope, I am taking my tools with me. Got to be karts in heaven.

Getting ready for he POR15 paint job. I got all the parts cleaned with Marine Clean. And then preped with Metal Ready. The metal ready will leave a zink phos. coating/etching on the metal. In the pics notice the white chalky powder coating. This coating is key for how good por15 performs. This Ody will never rust again. And have a rock solid paint job that you cannot chip. Even with a hammer.

To paint all these parts with Por15 the cost was $56. Sounds like a lot. But I think it is much better than powder coat. Gas will not touch it. And you cannot scratch or chip it with a hammer. $56 also encludes the silver color. No spraying and no primer. Just brush it on.

Here some more pics.

 

[bighead]

I got the POR15 pait job done last night. Once again POR15 worked great for me. No sanding envolved. Just wire wheels the best I could. POR15 lays so nice you would never think it was brushed on. I painted all these parts with 2 coats. I had some left over from only a pint. The key is to lay the first coat really light. The 2nd coat just lays on so smooth.

I painted all the parts but the wheels, nerf bars,J-Arms and seat pan with one pint of black. I would of been really close to running out of paint if I painted it all black using one pint. The brake cover in the 4th pic has lots of rust. It looks like I sanded it and then buffed the paint. Pretty good finish for little prep work. Not bad for $56 and no painting tools.
Here is some pics.

 

[bighead]

My father in Law got his first job in America. So the work pace has slowed some. Did get some work done today. Going to clean and install the engine tomorrow. Here some update pics.

Love that POR15 shine.

 

[bighead]

Been working a few hours on the Ody after work and dinner. The motor is now painted with Rebuilders Cast Aluminum spray paint. It has that dull cast color which I think makes it look new and unpainted. If you like the paint job make sure you buy the Rebuilders Cast color and not the Aluminum color.

This Ody engine has the Goki electric starter kit. To buy this kit on ebay would be close to $400 for a complete kit from A to Z. The kit converts the Ody electric system from AC to DC so you can run a battery so you have have the ES. My father in law is the wizard so I know little of what he did. The Stock Ody does not use a battery. So we had to convert the AC power to DC. Goki uses a simple inline diod to convert from AC to DC. My father in law did not like that to much. He said it was half wave charger. So we bought this. It cost $40 but the wizard said it would charge the battery better.

Universal 150 Watt full wave voltage. regulator/rectifier for 12 volt motorcycles and ATVs.
Designed to rectify A.C. output current to D.C. voltage.
Not a universal OEM replacement.
For use in single phase applications. Does not work in dual or three phase applications.
Floated ground is required.

We had to float the ground. We just removed the ground side terminal from the lighting coil and cut the grounding terminal off and solder a wire on the old ground wire/lighting coil and run it out with the other wires. Use the new wire and old yellow wire to the reg/Rec unit. Then hook up the + and - from the reg/Rec to the battery. (now you have to run 2 wires to all you lights for POS and NEG. Your frame is no longer a system ground)

Anyway just thought I would try to tell what we did. Perhaps some of you can use the tip in the future. Thanks to my father in law. All my electric problems are solved pretty fast.

I really like how small these Ody engines are. My clone is much bigger. Honda tucks them down nice and low as well. Nice engine cradle set-up on rubber mounts. These motors are 250cc at 16hp. They use a Salisbury clutch which I think is a 30mm tapered shaft.

Using all grade 8 bolts when I can. I have $555 into this Ody. I have all the parts to complete it. New front tires and seat covers as well. The only thing I do not have is good left side fenders. Thats going to cost me another $90 for good used. Or $300 for 4 new fenders.

Some pics.





Check out this 800cc Ody. I love the sound of sled engines. It's like they sing.

http://www.youtube.com/watch?v=8QT3vvakjfw&feature=player_embedded

 

[Casey Davis]

Hey bighead...have not heard from you.
I like the RCA paint. It has a nice finish and looks clean.
I have not had time at all to finish my Odyssey.
Getting side tracked all the time.
We did manage to pick up a "Scat-Cat" mini cycle like the one you posted on another thread. I'm restoring a another mini bike before it though.
I have a problem with falling in love with random toys to often.

 

[bighead]

Hey bighead...have not heard from you.
I like the RCA paint. It has a nice finish and looks clean.
I have not had time at all to finish my Odyssey.
Getting side tracked all the time.
We did manage to pick up a "Scat-Cat" mini cycle like the one you posted on another thread. I'm restoring a another mini bike before it though.
I have a problem with falling in love with random toys to often.

I have the same problem Casy. Was going to restore the yellow one first. But keep finding new deals. I am working to get 5 Odys for a big family camping trip in August.

The yellow buggy is going to get the whole 10 yards. I should be starting that soon. Maybe in within 8 weeks. Also going to do a Military themed Ody. But not full restore. Still nice but more of a budget build.

I have 3 engines I want to rebiuld as spares too. By the time I get to the yellow ody. I will know what I am doing.

I got your # I will call you soon. To be honest I just keep forgetting. Thanks Friend

 

[Bluethunder3320]

how did you get the engine so clean? paint or sandblast or both?

 

[bighead]

how did you get the engine so clean? paint or sandblast or both?

I use POR15 degresser called Marine Clean. Very good expensive degresser. I used a tooth brush and scrubed with Marine Clean. Pressure wash and heat for paint. I used rebuilders cast spray paint. A light dusting of primer. Thats it.

As far as Marine Clean? I never seen anything like it. It even removes rust. It cost so much that I only use it before right before paint. So I use that purple power stuff for first cleaning the part. I can degrease 2 times and still have grease in spots and corners. Wash the same parts in Marine Clean and everything is gone first time.

Another expample of the power of marine clean is the POR15 tank liner kit. You can take a dirty rusty gas tank. Dump in marinne clean to instructions. Dump it out and have a clean tank after wash out. Rust and all. I am pretty sure most normal degreaser would not stand a chance going head to head with marine clean. It was first developed to clean oil tanks on ships.

Never ask my about my POR15 journy. The stuff really amazes me to the max.

 

[bighead]

Got my go by the fly battery box made. No plans just started making it and come up with this. Also got the front suspension hooked up. Going to have a showdown with this ody this weekend. Hope to have it finished Sunday. I think all the fab and small parts paint work is now done. Lots of little stuff I had to do this week.

I went with a Lawn mower tractor battery. The are cheaper and more powefull than then ATV battery. With my updated charging system and the battery. I should be good to go. Also have newer pull start for back up.

I will be adding some more jam nuts on the threaded side bolts. I forgot to add them on the top before I took these pics. Using a threaded bar like this lete me add jam nuts on both top and bottom. Locked in pretty good this way.

Some pics

Ops pics before I got the sterring in. Steering is now in though. Smack smack.

 

[r97]

looks like its coming along nicely. that engine paint really works great!

 

[bighead]

Got the starter and battery wired up tonight. Did a test spin on the starter motor. Turns great with more than enough starting power. We used a ford starter solenoid bolted to the bottom of the battery box mounting bolts. The coil is in original location. The cdi box was fliped to the other side behind the coil. The recitfier was bolted to the original cdi location. I did not have to make any brackets to bolt up the electronics. This set up cost $72 to the build cost. But most Ody do not have ES. So scratch that if you keeping track of build cost.

Should have a big update this weekend. We just scored on a Flip Video mini cam thingy. Will make some vids this weekend.