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Old 10-11-2012, 12:31 PM   #1006
tommi79
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Location: Romagna, ITALY
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What about mine?
Just made, CNC machine produced, ready for sardinia rally!!! In case, I have more than 30 to sold.....

Weight: 400g. Suitable for 28mm handlebars.





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Old 10-14-2012, 01:53 AM   #1007
Pete640
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Thats a nice looking part for sure but not quiet the whole nav tower A640 is producing/trialing..
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Old 10-14-2012, 02:32 AM   #1008
NordieBoy
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Thats a nice looking part for sure but not quiet the whole nav tower A640 is producing/trialing..
No, but it is a nice simple rallye navigation bracket.
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Old 10-14-2012, 08:56 AM   #1009
640 Armageddon
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Nice work on the CNC Tommi, nice and simple !




As far as the Tower is concerned, I made some progress today. It needs some minor modifications but for the first prototype I am very happy and it is pretty solid even without bolting all the connections.

So... here it is




Pardon the quality but I was in the garage with my mobile phone only, I will post high quality pics in a future post... The lights come from ADVmonster, two wide and two spot beams...



That was a close call... Considerig the moke up was made from paper and the measurements where taken using a ruler at least it doesnt touch the fork.. it is ok at the moment... In Beta_2 these minor things will be fixed to allow more room for the forks ... I had to use these parts upside down to bring the extra lights higher, I may have to change this support but I am not sure. Time will tell



I envy these people who have a garage, a table to put everything on while I must have all the nuts and bolts on the floor while people come in to park their cars ... And holly mother of God whenever I forget something I have to pack everything, secure them, go home and then fo back to the garage again, unpack everything and continue ...




Sometimes I loose the odd washer or something but anyways...



Four mini toggles with four led lights ...











So, to sum up ...

1) It easier to install it if you have another person helping you or if you have the right tools for the job... I have given my Facom case to a friend so with the small Beta case installing all the nylock nuts was difficult so I put normal ones with nord locks in order to be able to adjust the position of the Tower, lights etc...
The final version will have both nord locks and nylock nuts.
2) It is very solid it does not look that it would vibrate so much but that is something I have to check when the bike fires up...
3) The side lights interfere with the KTM fairing ... The slots need to be a little wider and that will be done immediately
4) The main KTM switch interferes with the tower base ... (the cables coming from the bottom of the switch), Prototype 1 will be modified to accommodate the switch cables and the design will be altered so the final version is ok.... Question: The main switch has safety bolts that do not have anything to grab on to remove them as the nuts breaks when installing to prevent unauthorised removal... Is the only way drilling ?
5) The fairing needs to be modified. Well, the tower actually fits with the normal fairing but then again I like more the vertical fairing look and it allows for more positions to choose from ...

Now, the modular design of this thing allows me to remove the Roadbook and the IMOs and put back the KTM speedo with the switches I choose. See below...




Four toggle switches on top, with led lights, three illuminated rocker switches below the speedo and another three toggles on the right. Both the units above and to the right of the speedo are removable.
That makes either seven, or ten switches comfigurations ...





Another config above and just the speedo below...





The unit above uses the ''shaft'' that the roadbook assembly is fixed (the shaft like the one on Tommi's post above...) so by using removable connectors everywhere it will be a quick change. I will add the ability to add ICO's to the above so for everyday use you still have all the switches (lights, grips, fans etc) with a more of a ''normal use'' look ...
I will test the tower until the mid November and if it needs to be modified I will proceed to that end. At the end of November there is the 24hrs Rally Raid in which I will race test it and if it stays in one piece we are good to go ... It has so many degrees of freedom to adjust it so I want to make sure once you set it up it stays where it should... Last year another 640 Adv (not my own ) broke the subframe and threw away its number plate, the side covers and the rear rack without the owner noticing it ... I guess lighter is better

I received from speedaway.co.uk my new cable harness with all the other auxiliary cables and I have bought everything but the mini toggles so come Wednesday I will take the bike to a nice guy to sort out the electrics and do the minor modifications to the tower... I may just have enough time to anodise it black before the race just to see how anodising behaves in difficult conditions... It has to be anodised anyway to be protected from environmental attack...



oFF i gO !
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640 Armageddon screwed with this post 10-15-2012 at 12:29 AM
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Old 10-14-2012, 03:53 PM   #1010
Gany
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Nice work!

The main switch safety bolts... You can try using a sharp pin punch to tap the bolt around to undo it but it depends how tight they are and if they have been locktited. My bike had sheer bolts holding the key barrel on as well, however they would not budge with the pin punch no matter how hard i hit it. I ended up drilling out the head then use vice grips to undo them. Having removed them there was so much loctite there was no way they were coming undone with a pin punch... Maybe if i had of heated it first to break the bond:
http://wr250rforum.forumotion.com/t6...barrel-removal
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Old 10-14-2012, 07:43 PM   #1011
michael1968
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If you can get at the heads of the bolts cut a slot with a hacksaw so you can get a flat head screw driver on them.

Have you got anything to absorb the vibrations in there? My mk2 tower was a hell of a lot stiffer than my original, one thing I didn't count on was a lot more high frequency vibration, I had to add some vibration absorbers under the road book holder to stop it.

Nice work by the way!
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Old 10-14-2012, 07:59 PM   #1012
Pete640
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Nice work Dimitri - very nice detailed work.

You can grind the heads off the bolts using an air grinder with a carbide bit. The lock will slide off of the shafts and you can then remove them with vice grips. Then just replace when your ready with bolts that have a specific install tool and if you need to remove in the future you can easily. (if you remember where you put the part???)
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Old 10-14-2012, 11:45 PM   #1013
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Spent a great day with Kevin Muggleton of Team Redverz wiring up his Dakar bike.


Start of the day.


Kevin hitting the brake line re-route.


End of the day.


I think he was happy with progress.


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Old 10-15-2012, 04:22 AM   #1014
Pete640
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Hey Mr vestal,
I have one of the D2 pencil beams for my 950 tower project in the new year. I see in your pics he has used the tower plates to bolt through the cooling fins of the lights but how is he altering the pitch of the lights? Is there a arm or lug that Im not seeing?
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Old 10-15-2012, 05:18 AM   #1015
DRjoe
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Have you pulled the light out of its box yet Pete?
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Old 10-17-2012, 11:09 PM   #1016
RenoMoto
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Rally Navigator - Create and Share Navigation Roadbooks - Super Beta Release

Inmates:

This project has been in the works for awhile and I thought it was time to drop a teaser shot.

Rally Navigator - Powered by Google Earth.

Create - Print - Share.



Thanks to fellow inmates HogWild (Scott, the roadbook MASTER!) and GSNorCal (Dave at Rally Management Services) for education and inspiration.

Stay tuned - more to come!
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RenoMoto screwed with this post 10-17-2012 at 11:48 PM
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Old 10-18-2012, 01:01 AM   #1017
Pete640
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Wow. That is nice.
What size screen and type of tablet would u run it on?
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Old 10-18-2012, 01:49 AM   #1018
Brodovitch
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Quote:
Originally Posted by RenoMoto View Post
Inmates:

This project has been in the works for awhile and I thought it was time to drop a teaser shot.

Rally Navigator - Powered by Google Earth.

Create - Print - Share.



Thanks to fellow inmates HogWild (Scott, the roadbook MASTER!) and GSNorCal (Dave at Rally Management Services) for education and inspiration.

Stay tuned - more to come!
What about secondary roads in the tulip diagrams? Like crossroads, T-junction, V-split etc?
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Old 10-18-2012, 07:07 AM   #1019
c.vestal
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Quote:
Originally Posted by Pete640 View Post
Hey Mr vestal,
I have one of the D2 pencil beams for my 950 tower project in the new year. I see in your pics he has used the tower plates to bolt through the cooling fins of the lights but how is he altering the pitch of the lights? Is there a arm or lug that Im not seeing?
Hello Pete,
The lights pivot on the 6mm bolts that come with the lights. I designed the plates to have room for the lights to pivot.
So just loosen one bolt and pivot the light. I keep the Dually (4 led) just tight enough I can grab them and adjust without tools.
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Old 10-18-2012, 07:09 AM   #1020
c.vestal
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After hearing about this awesome project for so long, So happy to see this getting close!!!
I am posting in the Roadbook Creation thread.

Quote:
Originally Posted by RenoMoto View Post
Inmates:

This project has been in the works for awhile and I thought it was time to drop a teaser shot.

Rally Navigator - Powered by Google Earth.

Create - Print - Share.

Thanks to fellow inmates HogWild (Scott, the roadbook MASTER!) and GSNorCal (Dave at Rally Management Services) for education and inspiration.

Stay tuned - more to come!
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