frame lightening? suspensions mods for 10 yr old

[aircooledrider]

Just got a really ratty 92 blaster to move my 10yr old up from a really nice modified kasea 90 (it rips!) We stripped it down to the frame 1st day home (previous owner rattle canned the ENTIRE quad black, half of it is flaking off!) Father and son winter project, It is going to be dune only, He rides a ktm 65 everywhere else. Our goals are:
-improve and lower the suspension, extend swingarm, maybe frame? it's way to tall and tippy, son weighs 85lbs.
-make it as light as possible, can this frame be lightened anywhere (holes drilled? aluminum subframe?)
-clean running mild port 200, pipe, better carb? Not make it too fast, he's 10 remember
-hydraulic brakes all around or maybe just out back?
-basically make it like a new quad but setup just for him, and for much cheaper (got it for $400)
-and of course on a budget, maybe paint frame w/good enamel instead of powdercoat.
Anyway, any advice is welcome.
Thanks aircooledrider

 

[Whitty21]

welcome man, ken oconnor is your man to talk to about engine work, and as for frame lightning i wouldnt worry about it

 

[Kgibson]

Wide a-arms, axle and shocks set for his weight. My son is only 11 and has no problems

 

[acezeesawtooth]

^^^ yeah your problems arent that its to tall you just need to widen it... helps a rediculous amount even with just 3 inches in the rear...

 

[myusername]

as far as lightening the quad, i took off all the lights on my quad. i stripped the wiring harness, so there are i think three total wires on the quad. you can cut off all unecissary tabs on the frame. depending on where and how you ride you can get some 2 ply tires and maybe not super thick aluminum rims. they should be lighter than 4 ply that i think most tires are. cut your fenders down. aluminum handlebars. get rid of the bulky front brake perch. umm... aluminum front bumper. aluminum grab bar. the problem is, all this stuff gets super expensive and you dont loose a huge amount of weight and may not be practical

 

[Surfrjag]

flip the fronts and use a banshee axle in the rear.

 

[Blasterdude27]

The frame is on the weak side, I wouldn't drill any holes or cut out any supports, in fact gusset it. You can remove access tabs to save a little weight.
+3 or wider a-arms with shocks set up for his weight, you can keep the stock swinger for now but get a aftermarket shock and have it valved for is weight. aluminum rims, soft compound tires. simplified wiring, aftermarket pipe, remove the stock airbox and get a cfm aluminum airbox, cut fenders, no lights ( goes with simplified wiring ) aftermarket bars, ss brake lines with 03+ hydro brakes. Aftermarket aluminum bumper and grab bar.

That should make it ride much better and lower your cg, lighten it up and give it a bit more power. And then when hes ready to step it up you've got a great base.

 

[aircooledrider]

Wow,
so many responces already! Thanks guys

PS Kgibson that looks like a nicely setup mx blaster

 

[Whitty21]

Wow,
so many responces already! Thanks guys

PS Kgibson that looks like a nicely setup mx blaster

thats how we roll man lol

 

[sheeblast]

if you ride any trails, i would not use 2ply tires or thin alum rims. at least 4pl and .190" rims for trail. i have bent and seen people bend countless number of .160" rims, and never get .125" rims unless it is for drag racing.
as for making it lighter, you need to see which tabs are are not going to use and cut them off, also you can weld un any unused holes and smooth them out.
you can take off your front bumper and rear grab bar.

for suspension, some nice wider a-arms and axle will help out a lot. get some +2+1 a-arms. also get some good shocks that are sprung and valved for the weight and riding style of your son.

 

[DirtDiggler]

you won't have any issues , get a good pipe and silencer and when he opens that biotch up and she starts breathing he's gonna wet himself . I wish when I was 10 I had the blaster I have today , now I have a Banshee I gotta reign in . Enjoy the Sickness !!!!!

 

[aircooledrider]

Blastard,
I picked up a complete custom dune banshee since we were heading to the dunes so often, I know the sickness. I have rode everything and nothing compares to a modified banshee! Don't worry about my son, you should see him rip on the ktm65. Already got a plan going on this blaster: banshee axle,
+4 swinger, 400ex rear shock (or banshee if the +4 sits too high), wider a arms, etc.....
aircooledrider

 

[aircooledrider]

Any advice on what tabs/brackets I can strip off? Where are the areas I should gusset (swingarm pivot, etc...) This is a dune only quad. It will not have oil injection or anything that isn't needed in the dunes. That means no airbox, skidplates, practically a drag quad. I will probably even make a few carbon fiber parts for it. Thanks again!
aircooled