Africa Race 2008 - The Preparation Story

Discussion in 'Racing' started by schattat, Oct 27, 2008.

  1. schattat

    schattat Long timer

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    Hey guys,

    This thread is going to give a bit of an insight of my father preparing for the upcoming Africa Race Rallye in December '08, which is under the organisation of Hubert Auriol, a Dakar legend!

    I was asked by PackMule to start this thread, so here it goes!
    NOTE: I'll have to add some pics later on, since I haven't got a working scanner atm to scan some of the old-skool pics in...

    I'll first start of by telling you a little about the history of my dad's rallye career.
    It started back in '86, when he first took part in the Rallye Des Pharaons, which at the time was organised by Frenchman Fenouil, who had taken part in the Paris-Dakar Rallye several times.
    His bike was a then Yamaha TT600 59x. It was a very basic setup at the time, compared to what'll be used during the Africa Race, mainly due to not knowing what was needed or what was available (no internet!!). The tank was an Acerbis KTM/Universal tank made to hold roughly 30L (the one with the lid a bit to the right). As I said, pics will follow later on... If recall correctly, he was able to finish the race.

    Next year in '87 he took another shot at it, but managed to only complete a few of the stages in Egypt due to too many punctures in the rear tyre.
    This time, the bike was a lot better equiped with a large acerbis 40L with integrated paper air filter, and rear tanks. See here for pics, due to having good contacts to an Italian team known as ICO-MOTO.
    Participations followed in the year '88 and '89.

    The next major event was the Paris-Dakar in '92. In '93, it was another shot at the Pharaons. Dakar followed again in '96 and '98 (even have a TV interview of him during the '98 event in the desert!).

    In '00 it was a go at the Optic 2000 Tunisie and UAE Desert Challenge (PIC). Tunisie again in '05.

    BTW, all events were on a Yamaha TT600. The last 3 were on a TT600R though (Pics at the bottom of this page)

    The most recent event was the Rallye Des Pharaons in '07, the first event for him on a Yamaha WR450F (pics in upcoming post!).

    Hope that gave you guys a general idea of the whole history.
    If you've got a question, then please feel free to ask me anything!

    Now to the Africa Race preparation!
    #1
  2. schattat

    schattat Long timer

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    Here are the first steps of converting a standard '06 Yamaha WR450F in to a rallye machine!

    The project starts of with a standard WR450F on a cold and foggy January day in '07.
    [​IMG]

    We live in an area where houses are currently still being built, so we get the chance to use some of the empty land here to "train", even on that small hill.
    [​IMG]

    After removing the tank it's time to mount the tank support from Meca-Systems. It's designed to adapt the 28L/30L Adventure/Rallye tanks from KTM to the WR.
    [​IMG]
    [​IMG]

    After having removed the entire front part of the bike (forks, wheel, yokes, light, speedo, etc...) it's time to align the custom made instrument support on to the front of the frame.
    [​IMG]
    After 'perfect' :D alignment, the frame gets drilled!!!:lol3
    [​IMG]

    The entire support is held on to the frame by 5 M6 screws. Suprisingly stable considering the large weight mounted on to the support and the long leverage arm!
    [​IMG]

    Here seen from the other side of the bolts.
    [​IMG]
    [​IMG]

    Since the instrumental support is fixed up front, the plate which has the frame ID had to be moved.
    [​IMG]

    After fixing the temporary tank, it's time to see how the fairing fits.
    [​IMG]

    NOTE: The tripmasters seen here are OUR custom made ones!!! More info upon request!!! Also, the ugly LED lighting for the roadbook was changed later on, pics later on.
    [​IMG]

    Here we are attaching the aluminum support on to the frame.
    [​IMG]
    [​IMG]

    Final fixation.
    [​IMG]

    View of the entire support
    [​IMG]

    The orange 28L was later changed to a 30L version due to 2 reasons.
    1. More capacity :evil
    2. Paintable (note the yellow aint remains on the orange tank...)
    [​IMG]

    Frontal view:
    [​IMG]

    Rider's POV:
    [​IMG]

    And the remote, which is made all by myself!!!:D
    [​IMG]


    More pics will follow tomorrow, so stay tuned!!!
    #2
  3. Ladder106

    Ladder106 It's a short cut, really

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    Excellent !! More, please
    #3
  4. Tappet

    Tappet Feral

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    This is going to be very interesting. Subscribed!
    #4
  5. Mark950

    Mark950 Been here awhile

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    Ok I'm inteested...
    #5
  6. Hayduke

    Hayduke ///SAFETY THIRD/// Super Moderator

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    :lurk

    Thanks for the links to your Dad's pics. Very very cool.
    #6
  7. atgreg

    atgreg Africatwinarama Super Moderator

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    more please
    #7
  8. Gimmeslack

    Gimmeslack furthur

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    :lurk
    #8
  9. torags

    torags Long timer

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    Well done.

    Best of luck to your Dad. It appears he's in capable hands.... :thumb

    Rags
    #9
  10. whitey222

    whitey222 occasionally adventurous

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    ooh yeah... this is going to be good ! :lurk
    #10
  11. nfranco

    nfranco over macho grande?

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    Subscribed!
    How about some more info on the tripmasters?
    #11
  12. PackMule

    PackMule love what you do Super Moderator

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    Very cool, Tony!


    You can also embed your dad's old pics, just as you've done the bike prep pics, by getting the image url and placing it within IMG tags.


    [​IMG]
    (Hit "quote" to see what it looks like in code)




    :lurk
    #12
  13. c.herman126

    c.herman126 Been here awhile

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    I'm hooked. :lurk
    #13
  14. doyle

    doyle RallyRaidReview-ing

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    :lurk
    #14
  15. schattat

    schattat Long timer

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    Sure thing!
    Since my dad's an electronic engineer, it wasn't a big project to make a tripmaster that was able to withstand some tough riding through the desert!
    It's designed to only have the simplest features: Trip, Speed and Time. No more....
    Here a pic of the circuit itself:
    [​IMG]
    [​IMG]

    The casing for it was later changed to a grey coloured one, to make it kinda look like the original ICO VRL! (Pics later on)

    I myself have started a few projects. It's supposed to become a GPS which'll be controlled by touch. It's just a basic waypoint navigator, like the ones supplied by ERTF.
    Also, I've made a compass course repeater, which can be attached to the GPS main unit and receive the COG (course over ground). Still wokring ion it though....

    GPS unit with touchscreen:
    [​IMG]

    Compass Repeater:
    [​IMG]

    Both together:
    [​IMG]

    An example of the acutal 'real' devices used in rallyes (Source: http://blog.yoshirally.com):
    [​IMG]
    #15
  16. schattat

    schattat Long timer

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    Hey guys!

    Good to hear that you're all enjoying this thread.
    So on we go...

    Here are some pics of the bike ready 2 race for the Pharaons Rallye in '07.

    Frontal (shown with original KTM Adventure fairing, due to German road laws not allowing us to mount the GFK one for road use....):
    [​IMG]

    [​IMG]


    Rear:
    [​IMG]

    [​IMG]


    Added bash plate with container for compulsory 3L water (right side) + tool box (left side), which was earlier used on the TT600R:
    [​IMG]

    [​IMG]


    Rear shock upgraded to one from Öhlins:
    [​IMG]


    Cockpit, from rider's POV:
    [​IMG]


    Instrument closeup:
    [​IMG]


    Side view:
    [​IMG]


    View without faring:
    [​IMG]

    [​IMG]


    Fusebox mounted directly behind the Sentinel holder (Sentinel horn below that):
    [​IMG]


    Closeup of the elipsoid lights (fairing holes a bit too small??):
    [​IMG]


    Frame mount:
    [​IMG]


    Petrol pump mount (plastic gaurd later changed to aluminum one):
    [​IMG]


    Forntal view of bike with the Rallye GFK faring:
    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]
    #16
  17. schattat

    schattat Long timer

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    So the story goes on...
    Have fun!


    Bike loaded on the trailer with spare parts box (received during the Dakar '98!!) and spare wheels:
    [​IMG]

    [​IMG]

    [​IMG]


    Company car just happens to match the bike colour :lol3:
    [​IMG]


    After a few hours of driving through Germany, Switzerland and finally Italy, we arrived at the port, where the bikes, cars and trucks were loaded on to the ship. We met a couple of guys from GB (Justin Carter and Barry Richardson) who arrived just a short while after us. We helped them unload their bikes from their transporter.

    Here Justin's bike. A brand new KTM 525EXC with a fully loaded Meca Systems kit (me on the left; dad in the middle):
    [​IMG]


    Frontal view of the KTM:
    [​IMG]


    Cockpit:
    [​IMG]


    Rear tank:
    [​IMG]


    Front tank:
    [​IMG]


    Funny story here...
    Justin told us that he had received the bike just a few hours before he and Barry were supposed to leave GB for Italy. His 525 engine was increased to a 540 or so. Problem was that the bike hadn't been tested to see if it would still run. This later became a problem for him during the rallye, when his engine broke done during a stage. Dad rode passed him whilst he was waiting for the sweeper truck...

    One stupid thing with the Meca Systems kit ist that when you want to reach the carburetor to get hold of choke, you have to unmount the entire left tank, which means you're gonna have to also remove the seat. Pretty stupid design... :
    [​IMG]


    Organiser's truck for riders to load their boxes and wheels on to:
    [​IMG]


    Pics during the rallye will come later on, since I've just contacted the organisers to give me some of those pics!
    #17
  18. jack splash

    jack splash Two Sheds

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    Hey: NIce job on the bike. I'm always intrested in how all that equipment gets mounted.

    Jack
    #18
  19. schattat

    schattat Long timer

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    Hey guys,

    After a week of no updates, it's time for new pics!



    Frontal view, again... (my little modified XT125R in the background)
    [​IMG]


    Closeup of 'ICO' sensor setup (2 sensors in one) + magnet (both custom made)
    [​IMG]


    Closeup of new 'ICO' (left) and custom made readout for COG (course over ground):
    [​IMG]


    Entire cockpit:
    [​IMG]


    Behind the fairing:
    [​IMG]


    Rear tank mount (not really necessary nowadays due to the short autonomies, but just for that rallye look :wink:):
    [​IMG]


    Modified mount to allow the airfilter lid to be openend without having to remove the tank:
    [​IMG]
    [​IMG]


    Compulsory rear 'fog' light (custom made out of an aluminum block with 3 super strong LEDs). It actually blinks, but of course, you won't be able to see that in still photo ;) :
    [​IMG]


    Fuel line setup:
    [​IMG]


    The aluminum block between the fuel tap and tank is custom made to allow the other side of the tank to flow out of the other side (explained a bit weird :rofl) This allows the control of all the fuel from just one tap (both front sides and rear):
    [​IMG]


    Rear wheel removal tool (a hand made wrench wrapped to the swingarm with some rubber). Helps for a quick removal of the rear wheel:
    [​IMG]
    #19
  20. PPiA

    PPiA Pete

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    Very good thread.
    Am I the only one though, that hates those blinking taillights? I got stuck behind someone once using at night, and I was ready to take them off his bike with a hammer [​IMG]
    #20