Honda 919 Dual Sport Beast

Discussion in 'Some Assembly Required' started by Byrdman, Mar 17, 2009.

  1. Just Max

    Just Max I put the F in luck

    Joined:
    Oct 22, 2012
    Oddometer:
    381
    Location:
    PA Amish Country
    Makes me sad.. maybe he will post it up here first.. I would be a buyer :ear
  2. Byrdman

    Byrdman Fat guy on a little bike!

    Joined:
    Sep 27, 2006
    Oddometer:
    355
    Location:
    Streamwood, Illinois
    I&#8217;m still here guys! <?xml:namespace prefix = o ns = "urn:schemas-microsoft-com:eek:ffice:eek:ffice" /><o:p></o:p>
    The XR900R project continues to roll forward albeit at a snail&#8217;s pace. Two kids, two dogs, two rental properties, a taxing job, a mean ole&#8217; wife, and an expedition style 4Runner build have put the 919 Dual Sport back a bit on the priority list.
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    Since the last update I have been working on getting the engine cradle, the tail section, and the pannier mounts done.

    Here's the final engine cradle.

    [​IMG]

    I&#8217;m using a set of KTM 950A Hepco Becker panniers. As you can imagine, their immense size forced some significant changes to the relatively small tail section of the 919. I had to extend the entire rear of the bike 5&#8221; which added a ton of complexity.
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    [​IMG]

    Once the frame and internal structures were extended, I wanted to clean up the body work to make it look as factory as possible. I literally spent three weeks grafting two tails into one longer one. I laid down probably a mile of fiberglass and sanded until my hands were numb. I still have some cleanup to do but I&#8217;m beyond happy with the stock appearance of the new, longer tail.

    [​IMG]

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    I then set out to determine the perfect locations and orientation for the pannier mounting brackets. Where the weight sat on the chassis, how it looked, incorporation of the stock undertail, where my legs would be, the location of the kickstand, easy removal of the bags, easy removal of the support brackets, etc... All these factors were taken into account. I really wanted the install to be clean. I have seen other add-on pannier brackets and often, they look like they were a total afterthought. I decided to use a tube in tube, slide in type assembly to mount the brackets.
    <?xml:namespace prefix = v ns = "urn:schemas-microsoft-com:vml" /><v:shapetype id=_x0000_t75 stroked="f" filled="f" path="m@4@5l@4@11@9@11@9@5xe" o:preferrelative="t" o:spt="75" coordsize="21600,21600"></v:shapetype><o:p></o:p>
    <o:p>[​IMG]</o:p>
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    And as she sits today.
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    I did however find my inspiration at the local Toys-R-Us!
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  3. XR4EVER

    XR4EVER 919 excuses to ride!

    Joined:
    Aug 29, 2012
    Oddometer:
    1,141
    Location:
    Post Falls, ID
    :clap:clap:clap:clap:clap:clap:clap:clap:clap:clap:clap:clap:clap:clap:clap:clap:clap:clap

    It lives!!!!!!
  4. Jnich77

    Jnich77 Been here awhile

    Joined:
    Aug 22, 2012
    Oddometer:
    839
    Location:
    Orlando Fl
    Definitely one of my favorite builds...ever!!!!
  5. aposaric

    aposaric Garden mechanic ;-)

    Joined:
    Jul 6, 2007
    Oddometer:
    270
    Location:
    Zagreb, Croatia
    :clap It's alive :-) I wondered what happened to this bike :-) Do you have any plans, or rather, the time to finish it this year ?

    Keep us posted, really cool thread to read and watch pictures :freaky
  6. richarddacat

    richarddacat best jelly roll in town

    Joined:
    Nov 22, 2006
    Oddometer:
    3,592
    Location:
    Heart of Tennessee
  7. Byrdman

    Byrdman Fat guy on a little bike!

    Joined:
    Sep 27, 2006
    Oddometer:
    355
    Location:
    Streamwood, Illinois
    The wife and kids are out of town, perfect time to play in the garage.

    Got the front fairing partially mounted. KTM is a very unique company. Not one of the KTM fairing parts are symetrical from right to left! Took me hours to figure that out and it drove me all but insane!

    [​IMG]

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  8. Jnich77

    Jnich77 Been here awhile

    Joined:
    Aug 22, 2012
    Oddometer:
    839
    Location:
    Orlando Fl
    that thing should be a beast...lol.
  9. DRjoe

    DRjoe Long timer

    Joined:
    Sep 6, 2007
    Oddometer:
    5,386
    Location:
    Sunshine coast qld
    Nice.

    Are you going to do a ktm/Honda hybrid custom tank or are you sticking with the stock tank?
  10. Robmt78

    Robmt78 n00b

    Joined:
    Sep 21, 2013
    Oddometer:
    1
    Updates needed.
  11. shwaz

    shwaz Buckethead Wendy

    Joined:
    Aug 5, 2011
    Oddometer:
    619
    Location:
    the orange in the west
    there aren't too many search results on google for "honda 919 skid plate" but hell if it didn't lead me here.

    freaking love this build. delicious. :1drink
  12. RCmoto

    RCmoto Been here awhile

    Joined:
    Mar 7, 2014
    Oddometer:
    896
    Location:
    Southeast
    awesome! :clap
  13. slowpoke69

    slowpoke69 Been here awhile

    Joined:
    Feb 2, 2010
    Oddometer:
    606
    Location:
    So. Jersey
    How about it, inquiring minds and all that schizz!!

    It looks near done, is I hallucinating? :lol3

    Don't leave me hangin', I'm considering a similar fate for my 82 cb750f/ss, so I really want to see how it ends up.
  14. WeazyBuddha

    WeazyBuddha Carbon-Based Humanoid

    Joined:
    Mar 18, 2008
    Oddometer:
    5,097
    Location:
    RGV Texas
    Op hasn't logged in in awhile

  15. Byrdman

    Byrdman Fat guy on a little bike!

    Joined:
    Sep 27, 2006
    Oddometer:
    355
    Location:
    Streamwood, Illinois
    Yes, the project still lives!

    My cup runneth over with projects these days but The 919 Beast still holds her spot on the motorcycle lift. I have continued to source parts (LED headlights, hand guards, etc...) but I need to find time to get back out there and make some progress.

    Trust me, this project is near and dear to my heart and will run to completion.
  16. XR4EVER

    XR4EVER 919 excuses to ride!

    Joined:
    Aug 29, 2012
    Oddometer:
    1,141
    Location:
    Post Falls, ID
  17. shwaz

    shwaz Buckethead Wendy

    Joined:
    Aug 5, 2011
    Oddometer:
    619
    Location:
    the orange in the west
    This.
  18. Scubawerx

    Scubawerx Scubawerx

    Joined:
    Dec 19, 2012
    Oddometer:
    243
    Location:
    North Georgia
    You've got to appreciate the talent it takes to dream up and carry out such an idea. Hats off to you. (But those side boxes, well...the front of the bike looks great.)
  19. Byrdman

    Byrdman Fat guy on a little bike!

    Joined:
    Sep 27, 2006
    Oddometer:
    355
    Location:
    Streamwood, Illinois
    Thanks for the compliments.

    The side boxes (they're utilitarian ugliness especially) are a big reason I love adventure bikes. Of course, I also like Military vehicles with their no compromising, get the job done with no frills, designs.

    [​IMG]
  20. Byrdman

    Byrdman Fat guy on a little bike!

    Joined:
    Sep 27, 2006
    Oddometer:
    355
    Location:
    Streamwood, Illinois
    Holy cow, I have been "working" on this one for over 6 years!

    I needed some inspiration this morning so I jumped on here to drool over the other dual sport creations. Time to get my a$$ back out into the garage.