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Old 06-10-2012, 11:02 PM   #496
beechum1
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got my lights mounted yesterday. A few cursory pics to follow. Now to clean up the rats nest of cables... F.
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Rally Moto Kit /// Vendor Thread
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Originally Posted by flyingdutchman177 View Post
I used to say "one day" a lot. But then I got scared I would wait one day too long. So I am doing it all now
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Old 06-11-2012, 10:04 PM   #497
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Some finishing touches to be done, clean up the rats nest, make the tower for the road book, clean up the mounting plates.....












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Rally Moto Kit /// Vendor Thread
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Originally Posted by flyingdutchman177 View Post
I used to say "one day" a lot. But then I got scared I would wait one day too long. So I am doing it all now

beechum1 screwed with this post 06-11-2012 at 10:37 PM
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Old 06-12-2012, 12:02 PM   #498
crankshaft
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Looks good amigo! Consider changing the hand gaurds, I had a set of those and broke them pretty easily in the woods. The slot at the bar clamp is the weak point.
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Old 06-13-2012, 10:53 PM   #499
beechum1
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I can't figure out for the life of me, which push buttons those are on the HDB setups. I know they have to come from mouser, but I'm dumbfounded on that site. Lil' help?
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Rally Moto Kit /// Vendor Thread
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Originally Posted by flyingdutchman177 View Post
I used to say "one day" a lot. But then I got scared I would wait one day too long. So I am doing it all now
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Old 06-13-2012, 11:06 PM   #500
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Quote:
Originally Posted by beechum1 View Post
I can't figure out for the life of me, which push buttons those are on the HDB setups. I know they have to come from mouser, but I'm dumbfounded on that site. Lil' help?
Digi-Key Part Number 512PB-ND

Digi-Key Part Number 513PB-ND
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Old 06-15-2012, 03:44 PM   #501
beechum1
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newest drawing.

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Rally Moto Kit /// Vendor Thread
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I used to say "one day" a lot. But then I got scared I would wait one day too long. So I am doing it all now
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Old 06-16-2012, 11:06 AM   #502
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I received my HighwayDirtbikes Rally Frame

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Old 06-16-2012, 12:27 PM   #503
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Can't see this on their website. Source?
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Old 06-16-2012, 12:44 PM   #504
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Highwaydirtbikes.com - I think it'll be on the website later this month (or next? I forget if Paul said end of June or end of July ) .

I had a pre-production order in so I received mine before they were listed.

I'll post some more detailed pics as I install it
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Old 06-16-2012, 05:40 PM   #505
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I got started with the assembly.. here's what I've done so far:

All pieces are aluminum (anodized black) and the thing is amazingly strong (as witnessed last Wednesday when I watched him cartwheel his bike end over end )

As you can see in this photo, the bar risers actually bolt with 4 12mm bolts to the upper triple clamp making them incredibly stout:


Between the risers (of which they have different heights available) you can see the adjustable damper mount



The system is designed so that you can run one headlight, or two. You can run it with your stock fairing or a rally fairing (which they don't have done yet). For now I'm going to replace my stock headlight with a single Squadron unit and get rid of the pathetic excuse for a stock headlight; then I'll consider going with two squadrons or maybe a stryker and a squadron after they have the full fairing available.


Either way... I'm excited about doing some night riding now instead of fearing it with the stock candle

The squadron mount has a precise fit spacer with an boss built in for the anti-slip ring. You torque it down tight, the ring is made to crush out the right amount:


Here you can see I have the squadron mounted in the middle hole in the bottom location. Both mounting locations have 3 different mounting points giving lots of adjustability/tuneability depending on what you are using for lights


This is the backing plate for the squadron that allows mounting it to my stock 500's headlight mask


This spacer/re-enforcement ring is aluminum






Lots of cockpit space for roadbook, etc




...to be continued.
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Old 06-16-2012, 05:54 PM   #506
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That, is nice...
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Old 06-17-2012, 09:13 AM   #507
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Great pics Geek! I should have my version for the 690 next week and I'll post up some pics also. Looks really rugged, which is what I've come to expect from anything Paul makes. Take that beast for a night ride and let us know how the lighting works.
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Old 06-17-2012, 10:30 AM   #508
beechum1
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That is sexy. Simple and effective. Great Design Paul!!
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Rally Moto Kit /// Vendor Thread
Quote:
Originally Posted by flyingdutchman177 View Post
I used to say "one day" a lot. But then I got scared I would wait one day too long. So I am doing it all now
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Old 06-17-2012, 10:41 AM   #509
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So I got up early to get some wrenching in before we head up hiking in the mountains for the day... I wanted to get a mental grasp on what types of things I am still going to have to work out.. like wiring (yay! I have room to mount my horn ) brake line routing, etc.

Here's a bunch more pics...





Here's what makes this design so stout...
notice our triple clamps have two holes on each side (I took this photo last night when doing a spring swap)


Paul has designed his system so that the center bolts go through the risers like normal...


..but instead of the rear top clamp just bolting the clamp down, it goes all the way through and into that second triple clamp bolt meaning the entire system is bolted to the top triple with four 12mm bolts instead of two!





Since I already have the HDB system for crash guards and top clamp installed on my bike; everything bolted straight up quickly
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Old 06-17-2012, 10:42 AM   #510
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Looking at the tree...

Looking down from the top - you can see how the tree mount extends in front of the HDB instrument guard


The bottom of the tree goes in with two bolts to the existing holes in the lower triple


The top of the tree mounts up with four bolts


test fitting - everything aligns perfectly.

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