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    Fl250 junk pile resto
    #1
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    I purchased a 1978 fl250 that was mostly disassembled. I thought it would be a good project for a low price. I drove 4 hours to get it and was expecting to get a train wreck.

    When I picked it up I was surprised at how many parts there were. I also immediately saw some repairs I was hoping I would not have to perform.

    I will take pics soon.

    What I got:
    Full chassis
    Motor
    Full drivetrain
    Straight axle
    Straight wheels
    Functioning brakes
    Functioning parking brake
    2 good front tires
    Completely intact front tub
    Complete lower airbox
    Complete upper airbox
    Steering wheel functions
    Suspension is not seized.

    The bad....
    The origional cage is bent
    The front j-arm mounts are bent.
    There are some dings and a little damage to the frame.

    Why did I buy this?
    I really don't have much money but couldn't pass up a 100 dollar price. I do however have all of the tools to do any work.

    Why did I want one.
    When I was a little kid I wanted a gokart soo bad. Me and my dad built one and I was out tearing up the woods when I heard a loud buzz and saw the coolest thing come flying past me. Ever since then I have wanted one. Here I am 30 years later and I finally got one. I have built some very high end projects and owned a fabrication business for many years. I am currently an engineer for a large automotive manufacturer. Finances are tight due to a few years of battling a major health issue.

    My plans are to spend as little as possible to polish this turd.

    I will attempt to straighten the front beam, but may end up disecting it and widening it about 2+ each side. I have played with the idea of adding rear suspension, and have all the parts, but feel like I will take some of the character away from the fl250.

    I have a bunch of parts laying around.

    I have searched every site I can for ideas and successful repairs of the front beam, but not found much. I plan on doing alot of straightening and welding.

    I will be buying some tubing to build a cage, but am unsure what would be best for this little buggy. I have built several go-kart and dune buggies but they used much different OD piping and wall thicknesses.

    Wish me luck.......

    I would more than welcome any ideas help or links to good repairs. Also if anyone knows cheap sources for parts that would be wonderful.
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    Re: Fl250 junk pile resto
    #2
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    Oh yeah...I have 3 kids.

    My oldest two share a dune buggy that I traded a KTM 250/300sx for. And my youngest has a kart with a fully built predator 212.

    We have a 9 acre field behind our house that we have setup as a bunch of little tracks and obstacles. This fl250 will be a daddy toy and I don't like to spend money on me.
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    Re: Fl250 junk pile resto
    #3
    Member
    Join Date
    Mar 2016
    Location
    Ionia, Michigan
    Posts
    38
    Default
    Sounds fun, I know all about saving every penny you can lol. The build is part of the fun though right?
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    Re: Fl250 junk pile resto
    #4
    Member Mississippian's Avatar
    Join Date
    Jan 2016
    Location
    North East Mississippi
    Posts
    33
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    Welcome phydough. The FL250 is fun to ride and pretty quick. I placed an add on my local craigslist wanting parts and got pretty good results, parts cheaper than eBay. I am glad to see the FL250 forum is coming back to life. The front beam can be straightened by inserting a pipe as close to the diameter as you can and heating the beam. If the pipe is snug enough, you can leave it in the beam to reinforce it. The j-arms can be done the same way after they are reinstalled on the beam.
    Last edited by Mississippian; 04-11-2016 at 09:50 AM.
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    Re: Fl250 junk pile resto
    #5
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    I have thought about cutting the back side of the beam and straightening it and then multi pass weld it back. Then adding some additional gussets.

    Ideally I would like to replace the entire beam with one that is a little longer.
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    Re: Fl250 junk pile resto
    #6
    Senior Member
    Join Date
    Dec 2015
    Location
    Near Pittsburgh, PA
    Posts
    546
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    You bought yours for a similar reason I did.

    Check out my build and see what I'm doing by building a custom frame...you have all the running parts so might be a cool project.

    Look under builds for POS build.
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    Re: Fl250 junk pile resto
    #7
    Senior Member
    Join Date
    Dec 2015
    Location
    Near Pittsburgh, PA
    Posts
    546
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    Where are you located?

    I built a 2003 KTM 250SX into a 300SX...most awesome bike I have ever owned. It was a beast and not for the inexperienced rider!
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    Re: Fl250 junk pile resto
    #8
    Intense Moderator Rat4020's Avatar
    Join Date
    Oct 2009
    Location
    Cold Spring MN ...Dunz season's ust around the corner
    Posts
    4,148
    Default
    Welcome to MiniBuggy . Its always great ta see another pep get hooked on the buggy drug LOL
    The question is not if its gona roll. Its when ..

    That be some kind of church cruzzer or commuter bike thingy ?
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    Re: Fl250 junk pile resto
    #9
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    I am located in Rutherfordton NC.

    Not really new to the buggy world. Have a woods buggy with a pancake motor and a 3 rib. Have a manco silverfox with a built 212 (hemi), have a kandi gk150 (piece of junk)

    I loved the KTM, but I built it past my riding level. It was an absolute monster. Made my kx500 from back in the days seem like a lightweight.

    I have always had an affinity towards anything with a motor. But ever since I was 5 I wanted one of these. I just purchased a full unbeatable original cage. And bumper. I haven't even had a chance to look at it and I have already spent more than what I paid for it.

    It has some sort of nerf-bars on it that I haven't seen before, but I will incorporate them into the cage.

    Now all I need is rear tires.

    I will completely disassemble it coming up.

    I have a powder booth so I will powdercoat most of the parts before re-assembling it. The frame won't fit in my oven so it will get the old por15 treatment. I am going to make fenders for it from fiberglass. May even pop a mold off of them and try selling a few. They will be a more modern interpretation than the originals. I also will figure out a better ignition system (kinda what I design for a living).

    I also need to find a pipe for it that won't break the bank. Who any pipes from other motors fit this? I don't mind modifying.

    I already have a brand new seat and seat cover leftover from one of my buggy builds. That will get mounted with a layer of DEI goldwrap on the backside.

    I promise to get pictures.
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    Re: Fl250 junk pile resto
    #10
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    Anybody have some cheap atv tires?
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