The plastic misalignment was too much to ignore. So my dilema was get a 2011 frame and see if my motor fits, then worry about swingarm, linkage, moving my coil if need be (diff. mounting?), airbox adapter plate so that intake boot reaches the carb, etc. Looks like the crankcases are the same. Thanks Skully for your help on that. A little shy on that idea because I already bought a street legal frame for a 2008, already titled and registered. Didn't want to shell out another $1000 on that. Plus I still have wheels/ brakes to buy. The other route was to cut, re-position, and weld my current frame. Not a huge deal after considering the work of making a CR500 AF. Plus I planned on powdercoating anyway, so the frame would already be nice and freshly blasted to work with. It doesn't hurt my feelings to weld Cr-Mo, but I would prefer a bolt in affair. I have enough other "projects".
After a lot of contemplation which path to proceed, I decided to sell and just get a newer bike. I could have easily just done that in the first place considering all the $$ spent on parts so far. I sold the bike for the same thing I paid, so I didn't get hurt on that end. And I wasn't looking to score a profit. I just have to figure out exactly which model I want to get for a newer (or new maybe) bike, see what I have that will fit the new one, and sell the rest of the parts off. So probably, skid plate, exhaust, slipper clutch? maybe PDS shock cover depending which model I get, radiator hoses, maybe KTM catch can, 5-speed tranny, some orange billet engine accessories, etc.