The DirtBug Project is finished...

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Oh who am I kidding, ever since I started this kart and bike thing its been like an addiction. Basically what I have here is a DB30 DirtBug that given to me free by my cousin, her son no longer wanted it and she was trying to get rid of it. The engine still worked after a carb cleanup and I needed more power.

First thing I did is buy the adapter plate for the engine for these things, and mount my old 126cc Robin/Subaru engine with a clutch. That just was not enough umph for me. Next I bough a knock off 30 series torque converter from eBay, and this improved the launch significantly to the point where I could not keep the front of the bike down, but top speed was blah, all I could muster is 25mph, it was a 12 tooth jackshaft sprocket and 70t stock rear sprocket.

Next I bought a split sprocket adapter and got a 60t sprocket for the rear, much easier on the take off but still for some reason is topped out at 25mph, engine sounded healthy just did not have the might to push further.

Since I had to cut the chain tensioner to make the torque converter fit I had make one and weld it on. Look at those amateur welds, this was literally the first time ever I have welded so yeah, it looks pretty pathetic I will admit, but it is holding on there strong.

Final engine change, the trusty Predator 212 Hemi from HF. This one took some customizing to make it fit with the torque converter, and even after that the air cleaner element and the exhaust were not going to fit. I used a Dremel to modify the air intake and a user on this forum (Flyinhillbilly) donated a weanie pipe which was a perfect fit. I just cleaned it up and gave it some exhaust paint, along with a muffler from Tractor Supply. The paint did not stick to the muffler as I expected but I removed the paint and now its just bronze. In the end now it pulls very strong all the way up to 41mph according to my GPS app on my phone, about this speed I chicken out.

Finally tires, got some new Kenda TurfSavers and finally put them on today and absolutely love the ride, so much smoother than the old knobby tires that were on there. So there it is, even as I type this I want to customize even more.

--Dan
 

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Second set of pics.

--Dan
 

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Bbqjoe

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Everything looks good.
Interesting mod on a the air box, and that caliper is real close to the tire.

Judging from this pic I got off the internets, I think your torque converter is put together wrong. :D
 

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Hellion

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Looks great. I like those new tires; much better than the old knobbies where it looks like adding the knobs was an afterthought based on how sparse they are.

Do you have high temperature paint on the exhaust pipe?

I like how the engine seems to fill up the frame. Can you give us a ground-level profile/side view of the bike so we can see just how?
 

Whitetrashrocker

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That looks awesome. Good job squeezing it all in there.

Your butt might get hot with the tip of the exhaust right there...
And the claiper might rub with some road bumps and or a low tire.
 

mckutzy

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That's pretty tight space...
I would cut and reweld the caliper bracket, spaced over a bit with washers behind the disc to clearance the tire better...
 
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Do you have high temperature paint on the exhaust pipe?

Yep, high temp exhaust paint... header is fine I just did not clean up the muffler at all.

---------- Post added at 04:16 PM ---------- Previous post was at 04:15 PM ----------

That looks awesome. Good job squeezing it all in there.

Your butt might get hot with the tip of the exhaust right there...
And the claiper might rub with some road bumps and or a low tire.

Surprisingly after an hour of constant riding the seat did not get hot, although it was in the mid 60s outside so not hot yet.

---------- Post added at 04:17 PM ---------- Previous post was at 04:16 PM ----------

That's pretty tight space...
I would cut and reweld the caliper bracket, spaced over a bit with washers behind the disc to clearance the tire better...

That is a project I want still do, one of these days :)
 
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I like how the engine seems to fill up the frame. Can you give us a ground-level profile/side view of the bike so we can see just how?

Sure, pics attached...

--Dan
 

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pRoFiT

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Nice. So stock pred fit in there with tc...that must of been fun to do. Is the govener removed?
 
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Nice. So stock pred fit in there with tc...that must of been fun to do. Is the govener removed?

With some modification it sure it, I actually did have fun trying to cram it all in. Gov is still installed, I just moved the spring to get more RPM out of it. Verified with a tach meter and now the governor keeps it at about 4800 RPM. I am sure the engine life will be reduced and I am running the risk of blowing up the 212. Followed a user that had a post on this forum, all I basically did is back off the throttle stop screw all the way and the governor went from kicking in at 3800 before to 4800.

--Dan
 

Whitetrashrocker

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I'm sure 4800 will survive. I see mine doing 4500 all the time. So far so good. It doesn't sound like it's stressing so I'm good with it. I'm sure when you start revving 6k plus then I'd start worrying.
 
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