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Mini-Bike project

928 Views 23 Replies 19 Participants Last post by  fred's old chevelle
A couple years ago I bought a mini-bike to use as a pit bike when I go racing, and for the kids to play with in the back yard... it was a cheap, newer "Baja Racer" frame from the 80s or 90s with a 5hp Honda off a pressure-washer.

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A group of friends that I go to Road America vintage weekend with all bring our mini-bikes, and mine was arguably the ugliest one in the group...
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No cover on the clutch, and exhaust pointing forward were both annoying. I ruined a shoe on the clutch, so I needed to make a cover and made an exhaust pipe for it as well.
Here's a mock-up of a clutch cover made out of cardboard.
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I traced the template onto a flat sheet of 16ga...
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Plasma cut out the shape
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Hammered out the bends on the vice.
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Welded up the seams
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After a test-fit, I disassembled the bike.
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and had my son Cale sandblast it while he was set up to blast some parts for his '55 Chevy
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Bare frame all clean and ready for paint.
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Painted blue with some left-over paint from my Chevelle hood/trunk project.
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I got a springer fork off a vintage parts-bike. The chrome was bad, so I blasted it and painted the fork in gloss black as a base for the "chrome" paint I bought for my fiberglass bumpers... I needed to test spray something anyway before I finish those.
These needed to fully cure for a week before I could spray the "chrome".
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Clutch cover which I had loosely shaped in resemblance to the front fender of a '69 Chevelle needed a stripe, so a '69 SS style stripe was the obvious choice.
I didn't have any white basecoat, so I just used white epoxy primer and masked the stripe onto that.
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Painted blue again...
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finished result of the sheetmetal parts
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assembly begins
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Sprayed the "chrome" paint on the forks
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Couldn't leave the Honda sticker on the engine, so I had this custom Big Block Chevy air cleaner decal made.
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More assembly work
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Took the seat and some left-over upholstery from my Chevelle to "Augy" to have him re-cover it.
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1 - 20 of 24 Posts

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Discussion Starter · #2 ·
Hard to believe it's the same bike!
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Just need to route and connect the throttle and brake cables and it'll be done!
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1968 Chevelle Malibu, upgraded to a 396/TH400 from a 327/PG
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Looks awesome Derek! I love it.
 

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Looks great!!

Here's a before & after Lil' Indian I did about 12 years ago. I used to have about 10 mini bikes but sold them off a few years ago.

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Very cool! I have a '69 Lil Indian that is in similar shape, but had the wrong fork on it (Powerdyne Galaxy fork which I used on this build)
I'm looking for a correct Lil Indian fork with the folding handlebars like yours.
 

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Very cool! I have a '69 Lil Indian that is in similar shape, but had the wrong fork on it (Powerdyne Galaxy fork which I used on this build)
I'm looking for a correct Lil Indian fork with the folding handlebars like yours.
Mine was missing one OEM bar and the mount was broken. I bought some for a trail 50 or 70 honda to take their place.
 

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1970 Chevelle SS396
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Nice job on the paint and the build. I happen to have a few Honda mini bike seats I got at an auction I'm giving away. If you know of any of your mini bike friends that are looking let me know. They only need to pay shipping. The 2 on the top are gone. I'm in WI.
 

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nice job! I've got 1 minibike, always wanted on of those old style bike. jim
 

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There were 3 of us on mini bikes and I was 14 riding a borrowed mini bike.We're in the park with about 25 or more of the bunch were hanging out drinking beer and watching the idiots. I came blasting around a turn,at full throttle thinking how cool I looked. Until I caught one of the foot pegs and the bike kinda threw me.I hit the ground and slid about 20 feet. Sliding on the asphalt walkway doing my Superman impression except I was on the ground with my forearms scraping on the ground.Doh !!!
 
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Love it! The 5hp crossed flag decal is the icing on the cake
 
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I was going to say put a springer front end on it like a chopper, and with no rear suspension, build it like a hard tail.
You already have! Maybe just a single stagger pipe with glasspack and before you know it, people will think you're riding a big thumper.

It looks like you are having fun, and that is the main thing.
 

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I am jealous. I did the same, but not to that level, with an old Go Kart about 5 years ago. New HF crate motor, new floor pan, new clutch.

Great fun, but the grand kids only rode it twice a year, so I sold it to keep from having to maintain it.

Mini bike might be a good next effort.
 

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Lil Indian. That’s a name that brings back memories. I had a Rupp.
My buddy was tearing up the streets on his Lil Indian so someone called the cops. They came to stop him and my buddy gave them the slip. Well then the cops went to all the houses of those known to own mini bikes. They came to mine but I hadn’t been riding it and they touched the engine to feel if it was hot or cold.
Well my buddy who was the offender stashed his escape mini bike in the woods. Well his dad sold Lil Indians so when the cops came to his house he just pulled out a second mini bike they had with a cold engine. Guess the cops just left scratching their heads.
 
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