The Megalodon Project

Posted by Jason Merrell on 28th Jan 2025

The Art of Building the Ultimate Racing Minibike: The Megalodon Project

As a lifelong minibike enthusiast and builder, there's nothing quite like the satisfaction of creating something extraordinary from the ground up. Today, I'm going to take you through our most ambitious build yet - the race-ready Megalodon Minibike. This isn't just another backyard cruiser; this is a purpose-built racing machine designed to dominate the GPS180 Minibike Race in Graford, Texas. Grab your coffee, because this is going to be an in-depth journey into what makes this build special.

The Genesis: Why We Built It

Every great build starts with a problem that needs solving. In the world of minibike endurance racing, we consistently saw the same issue: bikes breaking down mid-race, crushing dreams and ending podium hopes. Speed is crucial, yes, but reliability is what wins races. This realization became our north star throughout the entire build process.

A man working on a motorcycle in a workshop.

Person working on a blue and red motorcycle in a workshop.

Person working on a small motorcycle in a workshop.

Starting With the Right Foundation

The journey began with the Mega Moto 212 frame, and let me tell you why this choice matters. Unlike lighter, more fragile alternatives, this frame uses thick-walled tubing that can take a beating. We've seen countless frames fail during racing, but the Mega Moto 212's robust construction provides the perfect foundation for a race bike.

After stripping the frame down to bare metal, we made the decision to go with a bold red and blue powder coat finish. While aesthetics might seem secondary in racing, there's something about a beautifully finished bike that makes you want to ride it faster. The powder coating also provides superior durability compared to traditional paint - crucial for those inevitable racing scrapes and scratches.

A small black and blue mini bike with large tires.

Close-up of a large, rugged tire on a vehicle.

Close-up of a motorcycle's front headlight and handlebars against a white background.

The Game-Changing Suspension Setup

Here's where things get really interesting. The stock Mega Moto 212 comes with a rigid rear end, which is fine for casual riding but brutal during a three-hour race. Our solution? The Mega Moto 212 Bolt-On Rear Swing Arm Kit. This isn't just any suspension upgrade - it's a complete transformation of how the bike handles rough terrain.

The kit features adjustable nitrogen shocks that can be fine-tuned for different track conditions. We spent countless hours testing different settings to find the sweet spot between comfort and performance. The addition of our custom Chain Guide was crucial here - when your suspension is actively working, chain management becomes critical for reliability.

Up front, we installed our Premium Front End Suspension Kit. The fully adjustable forks allow for precise ride height adjustment, which is crucial for weight transfer and handling characteristics. The lightweight billet aluminum triple trees reduce unsprung weight while maintaining rigidity. We topped this off with Tall GPS Billet Risers in Black, providing an optimal riding position for long-duration racing.

A blue and red mini bike on grass with a clear sky background.

Power and Performance: The Heart of the Beast

Now, let's talk about what makes this machine move. The Tillotson 225 Performance Racing Engine isn't just an engine - it's a masterpiece of engineering. We didn't just bolt it in and call it a day. Every internal component was carefully selected and tested.

The engine features a performance cam and Billet Aluminum Stage 2 Performance Parts throughout. But the real magic happens in the breathing department. We utilized a 24mm Mikuni Flatslide carburetor, tucked neatly against the frame using a 90-degree manifold. This setup not only looks clean but provides optimal fuel delivery throughout the RPM range.

The exhaust system required some creative thinking. Our Mega Moto 212 Tucked In Header Pipe stays within the frame's confines, improving safety and centralizing mass. Yes, we had to modify the rear fender, but the performance gains were worth it. The pipe is braced under the seat to prevent failure during aggressive riding - another lesson learned from racing experience.

A blue mini bike on a shelf in a garage workshop.

The Innovative Dual Tank Solution

Here's where we really got creative. In endurance racing, pit stops kill your race position. Our solution? A dual tank setup using our UniTank feeding into the Tillotson 225 Gas Tank. This modification allows us to run the full 180-minute race without refueling - a massive competitive advantage that has helped us secure several podium finishes.

Wheels, Tires, and the Ground Game

The wheel and tire combination on a race bike can make or break your performance. We upgraded to 10" Machined Aluminum wheels for their reduced weight and superior strength. Paired with 21x7-10 Offroad tires, this setup provides excellent ground clearance and superior traction in varied conditions. The larger diameter wheels also help smooth out rough sections of the track, reducing rider fatigue.

Close-up of a motorcycle tire and wheel on grass.

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The Details That Matter

We finished off the build with Renthal Dual Compound Grips - a small detail that makes a huge difference during long races. The Juggernaut 30 Series Driver provides optimal power delivery, with different stage kits available for fine-tuning the engagement point to match track conditions and riding style.

Real-World Performance

This bike isn't just a showpiece - it's a proven performer. In its first outing at the GPS180, we ran the entire three-hour race without a single mechanical issue, maintaining competitive lap times throughout. The suspension setup allowed our rider to push harder in the latter stages of the race when other competitors were struggling with fatigue.

Building Your Own Race Winner

For those inspired to build their own race-ready minibike, remember that success lies in the details. Every component must work in harmony with the others. Take time to test and adjust. Learn from each ride. And most importantly, build it right the first time.

The Megalodon project represents countless hours of development, testing, and refinement. It's a testament to what's possible when you combine the right parts with proper assembly and thorough testing. Whether you're building for competition or just want the ultimate performance minibike, these principles remain the same.

Remember, in the world of minibike racing, the fastest bike doesn't always win - but the most reliable fast bike usually does. That's exactly what we've created with the Megalodon, and we couldn't be prouder of the result.