I see some people still want info about gusseting the frame, although you can find it all over this forum. I also think it's good to post all your pics and info that can help our fellows in doing the gusset job in a single topic. Someone said maybe it could be pinned, but we'll have to see how useful this one will be.
So people, go ahead, if you got pics that can be useful, please post them with a little bit of info, or just send them to me (frefre@pandora.be), I'll host them.

This was the article in Dirtwheels where they tested the Lonestar gusset kit, many tnx to Hooptybug for scanning this article!:
link removed, sorry guys
link removed, sorry guys
This gusset kit covers all possible weaknesses, so this frame is ready for some hard (ab-?)use.
Many people go with less gussets (2+) for the most critical areas, such as the upper front shock mounts.
You might think of gusseting your frame when you start to see this at your upper front shock mounts (or anywhere else near the weak spots, see pics):

(tnx to Norcal KFX400)
Paint chipping is usually a sign of the metal flexing, and cracks can be formed.

This is Hooptybug's gusset job:
Hoopty's gusset job
Hoopty's frame PC'ed

A very good page with pics tnx to Jeffksf
Jeffksf's gusset job

DadsZ400 Gusseted and painted frame (?)
Front shock mounts gusset
According to Z400ACDC Dupli Color T-183 gray is a perfect match. (Auto Zone)

Badercarma's Solution:




Tricky17's Gusseted and PC'ed frame:


oh btw, some recommend the Arens Frame Brace as a bolt on device that should prevent your frame from breaking at the upper shock mounts. But gusseting is imho the only good solution when you ride it hard or you want to feel really safe:

Tnx to suzukiz400.

Here's Bare Performance's basic gusset kit:


this is the original topic: http://z400central.com/invision/index.php?...topic=16941&hl=

Can someone grab their nearest dirtwheels and flip thru the front making sure it doesn't state that reproduction of their magazine without their consent violates any copyright laws.

If thats the case I will have to yank the links of the scanned pages.

I want to find out first cause they are actually good info.

According to Dirtwheels "Nothing in this magazine may be reprinted whole or in part, by any means, without the express permission of the publisher."

Sorry to kinda spoil the thread but at least central won't be sued :(

Well TX400 we got to delete your message to cause you baiscially reprinted part of it. But you did give them credit such as Fre did. I know i am bad

THanks for including my webpage, I feel honored.

Thanks, let me know if you have any questions we can help you with. We will also be adding four pieces to our kit. So we will have the 9 piece kit for $45 and the 13 piece kit for $55. PM me if interested...

yes I understand, I have been thinking about that too.

What if I would email dirtwheels to ask for their permission to post the article here on this forum?

And I just did :)

Who knows we get their permission, asking it doesn't hurt...

If anyone has pics or wants to take pics from their frame (cracked or gusseted) or give hints ant tips about gusseting your frame please post! Many will greatly appreciate!

Great job putting all this together..

it was not really my idea, but I wanted to do it because I have to give something back to z400central for giving me all the help I ever needed.

for the gusset on the bottom of them frame where the bars for the Suzuki Nerf bars go through will they still be able to go through with the gusset there?

yeah I think so, if you do not make them too large

Yes, we took that into consideration when designing that piece...

how much for that piece?

His 13 piece kit includes those. It also includes two braces for the upper steering stem mount. The rest of the kit can be seen in Bare Performance illustration. As mentioned before the price for the 13 piece kit is $55.

Just a few pics of my recent project.

very nice did u do anything to the subframe?

This is what happened to my friends KFX, his got replaced for free by his dealer even after the warentee had ended but since I had bought mine used I didnt think I would be able to get it replaced so I just welded it.

http://www.myatvs.homestead.com/files/P7020021.JPG
http://www.myatvs.homestead.com/files/P7020023.JPG
http://www.myatvs.homestead.com/files/P7020027.JPG
http://www.myatvs.homestead.com/files/P7020030.JPG
http://www.myatvs.homestead.com/files/P7020037.JPG
http://www.myatvs.homestead.com/files/P7020040.JPG
http://www.myatvs.homestead.com/files/P7020041.JPG

I also crashed my quad into a stump going real fast and bent the frame, I need to take more pictures of the extra braces I added after I had it bent back.

I didn't do anything to the subframe. If it breaks I'm going to get an aftermarket one. The are a couple of companies that make them.
I'll be riding this in the opening round of GNCC on January 31st in Gilmer Texas.
Darren

that gusset looks good......

biggest thing on gusseting is its best to do it on a fresh frame.... You wait til it cracks, then usually its too late by then....

do you have to strip everything off the frame to do the basic gussets on the front shock mounts. Can you just gusset the parts with just the plastics off? also, where else on the frame is vitally needed where it has been cracking, cause i plan to get LT suspension and all that but dont plan to race mx, only big jumps and stuff. but damn, that seems like it would take an eternity to strip the frame completely. -Angelo

Yeah, I would like to know that too.

With the Bare Performance kit you only need to remove the front plastics to install the gussets. When installing the top 2, by where the steering stem mounts it may be a good idea to remove the gas tank (dont want stray sparks blowing you up) but make sure you mark where the tank rests, so your welder doesnt weld the gusset in the way of the tank. Easy to follow instructions are included, but better safe than sorry, especially if someone else is doing your welding. Let me know if you have any more questions...

Matt Bare

I did my shock mounts a few months before I did this current gusset work. It did not require taking everything off. I removed my front plastic, covered the rest of the quad with a moving pad and welded the gussets in. A couple months later when we took the quad apart they still looked great.

badercarma


I have been battling with Kawasaki to get my frame replaced. They told me they don't replace a frame if its out of warranty. I'm in contact with a few lawyers and am ready if needed to use legal action. Does anyone know of other people in my position or that had there frames replaced by Kawasaki? This would help out alot and provide me with some much needed leverage! Thanks in advance.

Bare Performance is now offering the full gusset/weld/powdercoat deal. For[SIZE=7]only $349[/font] you ship your frame to us, we weld our 13 piece gusset kit on ($55). Then powdercoat your frame a color of your choice and ship it back to you. All for only $349. This is an introductory rate and will go up soon... Pictures of our work will also be available soon. For those of you who have already bought the gusset kit but not welded it in yet, you can subrtract the $55. PM me or email mattbare@bareperformance.com with any questions...

Do you have any idea how much it would be to ship a frame from Texas to yall

you have a pm TXZ400

hey matt tonight i will have my frame all done being gusseted so ill take some pictures of your awesome gusset kit installed on my frame thanx again man!!!!

I also finished my frame with your kit.

Turned out great!

we just made some gussets based off of the picture in dirtwheels and we installed them today im sendin it out this week for powdercoating! 8)
now i wont have to worry about the frame anymore

heres my quad as of now :x

caint wait to ride it again!

shock mount brace

welded in the cracks and weak spots

some braces

some more


this cost me 10 bucks to do myself instead of hundreds for someone else 8)

looks good! 8)

Tnx for posting!

What color are you going to powdercoat it?

a bright rich red and the a-arms sub frame and swing arm are gonna be black 8)

sounds promising 8)

i sent out the frame and sub frame for powdercoating today but the a-arms and swing arm will have to wait :uh

lol i sent my gusseted frame to pappy tonight and the shipping only costed $17.00 im getting it powdercoated trans blue

can't wait to do mine! :whoa

yea i sent mine to pappy three weeks ago and it only costs $15....you dont have to crate it or anything just put a tag on it and ship it

yea just in case i put mine in a box with the subframe inside the frame

When you guys did ur gussets, did u like sand the paint off or anything to take the paint off? Or did u jsut weld em right on there?

i just welded them right in....the powdercoater did the stripping before he powdercoated it

mine came out great

Could someone scan in the gusset template for the shocks so people here could use it? I just want to do the shock gussets and don't want to buy the entire kit. I am sure a lot of people on the forum would use it. What issue was it in?

i wanna do the gusset myself, and for everyone who made there own how heavy of steal plate did u use?

I gussted my frame... Ill have my friend takes some pics and ill post em.

I think the kit I got uses 3/16 inch steel plate? Very hefty from Bare...




On another topic what kind of welders are you guys using? Would a small mig with-out gas work? Like a 120 volt 80 amp with shielded wire? I always wanted to get into welding and was just wondering how well these entry level units work?

I was wonderin the same thing, cause my dads a welder and he said he would rather tig weld them in but he dont have a tig set-up, but we got a mig welder and is that what u guys r using? Mig?

Had my shock gussets installed. He used a Mig, Tig would be neater though. Still curious if those cheap 200 buck migs would do the job?

I had mine done with a mig (those are the ones that u dont have to have a stick of metal held up to it right? It automatically feeds the metal out?)