ADVrider

Go Back   ADVrider > Riding > Racing
User Name
Password
Register Inmates Photos Site Rules Search Today's Posts Mark Forums Read

Reply
 
Thread Tools Search this Thread Display Modes
Old 12-30-2014, 01:30 AM   #1
michael1968 OP
Studly Adventurer
 
michael1968's Avatar
 
Joined: May 2009
Location: Newcastle, Australia
Oddometer: 838
KTM 450 RFR Carbon Fibre Bashplate Repair

Hi all,

I thought I'd share a few pics to help pass the time before the Dakar kicks off...

I was asked by fellow advrider Waldecker to repair the bashplate from his recently aquired KTM 450 RFR. The bike has a little history, it was the bike Aussie Ben Grabham finished 15th on in the 2015 Dakar.

You can see what I believe is the exact bashplate in this pic, the damaged area's match up.



These bashplates cost around 1200 AUD from KTM so obviously it's worth a shot trying to repair. You can see in the pics below that the part is made up of a number of layers of carbon, a few layers of Kevlar and then more carbon. The Kevlar has done it's job and held the bashplate together but once the fibres of the Kevlar are exposed they no longer add strength to the part and also allow water and dirt into the part causing it to delaminate. These need to be re-covered with epoxy and also more carbon added to bring it back to it's original strength and shape.

As I received it;
michael1968 is offline   Reply With Quote
Old 12-30-2014, 01:42 AM   #2
michael1968 OP
Studly Adventurer
 
michael1968's Avatar
 
Joined: May 2009
Location: Newcastle, Australia
Oddometer: 838
First I needed to fill the larger holes and glue one of the pieces in the right place as it had a ~30cm crack and was flapping around. I used a mixture of epoxy resin and milled carbon fibre as it's really strong filler and is compatible with the original part. It looks ugly but works and you won't see it in the finished part.

I've already sanded the filler back in these pics;

michael1968 is offline   Reply With Quote
Old 12-30-2014, 02:07 AM   #3
michael1968 OP
Studly Adventurer
 
michael1968's Avatar
 
Joined: May 2009
Location: Newcastle, Australia
Oddometer: 838
Next I removed any delaminated carbon and sanded the areas surrounding the damage to ensure a good bond. I laid 3 layers of carbon twill in the damaged areas, I used epoxy resin again as the matrix. I'm 99% sure that KTM would have used an epoxy (prprobably pre-preg) in the origial part but epoxy sticks to most other resins so it's a safe bet anyway.





Then I layered the materials for vacuum bagging, first peel ply to stop everything sticking to the part, then perforated film to control the flow of resin out of the lay up and then some breather cloth to absorb the excess resin. All that goes in the bag;



Now with the vacuum pump turned on, you can see the excess resin already being squeezed into the breather cloth.

michael1968 is offline   Reply With Quote
Old 12-30-2014, 02:11 AM   #4
michael1968 OP
Studly Adventurer
 
michael1968's Avatar
 
Joined: May 2009
Location: Newcastle, Australia
Oddometer: 838
Here's the part removed from the bag and with the various layers pulled off.




More later.
michael1968 is offline   Reply With Quote
Old 12-30-2014, 04:17 AM   #5
twotyred
Practising Recedivist
 
twotyred's Avatar
 
Joined: Feb 2006
Location: Bruthen Victoria
Oddometer: 2,204
Cool!!!
__________________
If you succeed at first...don't look surprised!!

More enthusiasm than ability!!
twotyred is offline   Reply With Quote
Old 12-30-2014, 12:08 PM   #6
LocuL
Gnarly Infantry
 
LocuL's Avatar
 
Joined: Dec 2006
Location: Denmark - Jutland
Oddometer: 1,351
1200 aud...thats a steal
__________________
KTM 950(1190) Adv-s, Soon to be Project 1190
KTM 530 EXC-R 08
LocuL is offline   Reply With Quote
Old 12-30-2014, 09:31 PM   #7
The Griz
North Forest Rider
 
The Griz's Avatar
 
Joined: Nov 2008
Location: Minnesota
Oddometer: 3,787
Awesome! Great work!
The Griz is offline   Reply With Quote
Old 12-31-2014, 12:43 AM   #8
michael1968 OP
Studly Adventurer
 
michael1968's Avatar
 
Joined: May 2009
Location: Newcastle, Australia
Oddometer: 838
Thanks guys!

At this stage I could have just left the bashplate and it would have been perfectly functional. But we want a little bit better than perfectly functional and since I'll be taking a mould from it I want it to be as close to the original shape as possible.

The above picture doesn't look too bad but you can see below that the carbon hasn't quite been built up to the original level.





So after a little sanding;




I laid a few more layers of carbon and vacuum bagged again;



michael1968 is offline   Reply With Quote
Old 12-31-2014, 12:45 AM   #9
michael1968 OP
Studly Adventurer
 
michael1968's Avatar
 
Joined: May 2009
Location: Newcastle, Australia
Oddometer: 838
I then repaired the inside using the same method, this time I also added some extra kevlar;



michael1968 is offline   Reply With Quote
Old 12-31-2014, 12:52 AM   #10
michael1968 OP
Studly Adventurer
 
michael1968's Avatar
 
Joined: May 2009
Location: Newcastle, Australia
Oddometer: 838
Next, to restore the original finish and also fill in any small dents that I missed with the carbon, I coated the whole thing with epoxy, it looks OK in the pics but is still a little lumpy, I'll give it a light sand and a final top coat after my new years hangover wears off...



michael1968 is offline   Reply With Quote
Old 12-31-2014, 01:40 AM   #11
nry
.
 
nry's Avatar
 
Joined: Jan 2008
Location: .
Oddometer: 1,538
Any idea what sort of an impact caused the damage in the first place ?
nry is offline   Reply With Quote
Old 12-31-2014, 02:22 AM   #12
michael1968 OP
Studly Adventurer
 
michael1968's Avatar
 
Joined: May 2009
Location: Newcastle, Australia
Oddometer: 838
Quote:
Originally Posted by nry View Post
Any idea what sort of an impact caused the damage in the first place ?
Ben Grabham and whatever got in his way



Seriously though it looks like the damage happened over time, plenty of dirty and leaves wedged in between the carbon and kevlar.

I noticed some similar damage on the bashplate of Simon Pavey's bike when it was being loaded in for Dakar, I hope he's got a new one for the start.
michael1968 is offline   Reply With Quote
Old 12-31-2014, 02:40 AM   #13
nry
.
 
nry's Avatar
 
Joined: Jan 2008
Location: .
Oddometer: 1,538
I guess full Rally bikes and unknown tracks make for lots of bottoming out even on a 450RR and not just my bike. Nice repair.
nry is offline   Reply With Quote
Old 12-31-2014, 02:51 AM   #14
640 Armageddon
-oo-
 
640 Armageddon's Avatar
 
Joined: Mar 2009
Location: Greece
Oddometer: 2,827
Hey Michael,

Nice job !
Do you have any idea of the weight of the thing? Do you think it would be better for example to make it thicker? Problem I see is that one cannot repair this one the spot, but obvisouly not relevant to this case, just wondering for Simon, although I am sure he will be able to trace a spare iin Dakar if need be. I am wondering fiber over polymer here, and wanted you feedback in this case. I suspect the plate to be flexible in a sense, I mean the bike lands on a rock, it will flex and not behave like AL alternatives. Polymers with addidives hace strong penetration resistance, so I was wondering if a mixed material bash plate could make the difference...
__________________
Aurora Rally Equipment - Rally parts with lifetime warranty
"Do or Do Not. There is No Try" - Yoda
640 Armageddon is offline   Reply With Quote
Old 12-31-2014, 01:37 PM   #15
pilo
Rhymes with below
 
pilo's Avatar
 
Joined: Feb 2005
Location: SLC, UT
Oddometer: 944
Great job on the repair. I love seeing excellent layup work. It seems like the damage starts in the front 'corners'. I wonder if a stainless corner guard would delay the damage from coming back. It almost looks like something needs to give a little initial protection.
pilo is offline   Reply With Quote
Reply

Share

Thread Tools Search this Thread
Search this Thread:

.
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On

Forum Jump


Times are GMT -7.   It's 05:25 AM.


Powered by vBulletin® Version 3.8.5
Copyright ©2000 - 2015, Jelsoft Enterprises Ltd.
Copyright ADVrider 2011-2015