For this project we used a basic frame and fork assembly manufactured by Azusa engineering . Azusa has been in the Go Kart and Mini Bike business since 1960. The frame is manufactured and welded here in the USA. It has a very cool retro style Mini Bike look, but has it’s short comings when it comes to tires, rims, brakes and controls available from the manufacturer to build it. Our goal was to upgrade all the components and take this to another level capable of handling one of our built competition level 212 Ducar racing engines.
Azusa 3545 frame and fork set.
First of all we noticed there is no steering head stop on the Azusa frame which will cause the fork cross bars to carve into the frame tubes damaging any paint work we would do.
So we fixed this by fabricating up a steering stop to protect our new powder coating job.
We removed existing flimsy rear axle mounts and drum brake anchor from frame. Then
lengthen the wheelbase by adding custom fabricated rear gussets to frame tubes with 12 mm axle mounts.
This will allow us to use 10 inch pit bike wheels with a sport/street tread tires.
We custom made a center stand.
Fabricated and welded in fuel tank mount tabs to top frame tubes.
A front mount to use a MCP billet brake caliper was fabricated and a mount anchor tab for the fork tube.
Also rear brake caliper mount and anchor tab for rear brake system.
We added fender mounts for our custom Carbon fiber Fenders
And rear wheelie bar mount tabs.
A foot peg cross bar was added. This supplied some extra rigidity to the front frame tubes
and a solid peg mount instead of the flimsy Azusa clamp on peg system.
3 Stage powder coating with clear coat.
Color- #FF2800 Ferrari Red
And last we fabricated a Chrome Molly Wheelie Bar
Engine build time!
The Ducar 212 was chosen due to its added block strength and reliability.
Modifications and additions.
Block modifications for governor and oil sensor removal.
High compression flat top piston.
Milled and ported 14 cc head, 36 lb Valve springs, stainless steel valves, alloy spring retainers with automotive style keepers.