KTM 640 Rallye skid plate (Group effort)

Discussion in 'Thumpers' started by KTM640Dakar, Apr 1, 2005.

?

Assuming it's constructed like the typical KTM factory piece...

  1. I'd buy an aluminum storage/bash plate if priced below $300

  2. I'd buy an aluminum storage/bash plate if priced below $400

  3. I'd buy an aluminum storage/bash plate if priced below $500

  4. I'd buy an aluminum storage/bash plate if priced below $600

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  1. KTM640Dakar

    KTM640Dakar Motorsick

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    I wanted to pose a question to everyone about the Rallye skid plate toolbox that everyone wants but know one can afford. There seems to be enough talented people on this forum that we could as a group build these skid plates if we all helped. My idea is to build skid plates with the tool box or boxes to oem skid plates. I have the ability to weld aluminum all day long, but do not have a way to stamp out the indivdual parts. If someone in the forum could stamp out the aluminum I could weld them to either an OEM aluminum skid plate or an after market one. What does everyone think? There seems to be about 30 of us on this thumper forum at any one time.
    #1
  2. ChrisC

    ChrisC Amal sex?

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    You might want to take this up with Flanny before you go much further. He's very experienced at this endeavor...
    #2
  3. Renazco

    Renazco Formerly AKA Boejangles

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    After much thought, I reconsidered adding more weight to the front end of the bike and decided to build a rear tool box. I would like to see a better skid plate though as the stock one seems really flimsy.
    #3
  4. soloyosh

    soloyosh Dad and husband

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    I can't offer any manufacturing help but if it'll fit my SXC, I'll pony up cash for it.

    Brett
    #4
  5. scuzzy

    scuzzy ...naked, cactus dancing

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    Likewise :thumb
    #5
  6. overlandr

    overlandr Dystopist

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    Seem to recall that there was a lot of talk around a year ago about a group project on a custom design one at group prices. The thread will be there somewhere - google?
    #6
  7. BlitzBike

    BlitzBike LC4 Pilot

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    Flanny made blueprints but, could not get the fabricating price down to an acceptable level so he refunded all of our monies.
    #7
  8. KTM640Dakar

    KTM640Dakar Motorsick

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    Well Flanney, how much of the cost's were associated with welding?
    #8
  9. Arch

    Arch Incurable Gearhead

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    Flanny's a 950 guy now, but as mentioned above, the rally bash/tank thing didn't prove affordably doable. Search through threads started by Flanny (scroll down) to see how it all unfolded.

    Your best bet is try & find one overseas from the usual suspects, and they do turn up for sale from individuals every so often.
    #9
  10. meat popsicle

    meat popsicle Ignostic

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    I think these fellas are mistaken, KTiM had one fabricated for himself for the low low price of 250... a third of what they ask for new ones. This is a good possibliity, just need someone who can stamp aluminum parts.

    Loaded?
    MotoMike?

    who else am I forgetting who has mentioned fabrication...? :ear

    One suggestion right off: the KTM rallye skidplate boxes bolt on and off, so you can remove them but still keep the skidplate. This would also make em easier to deal with as people wouldnt have to send you their skidplate.

    The Thread:

    http://www.advrider.com/forums/showthread.php?t=11403
    #10
  11. KTM640Dakar

    KTM640Dakar Motorsick

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    I would assume most everyone has a drill. We could fab up the boxes and leave it to each person to drill the tabs and flanges on their own. If we keep everything square it may be easier to bend the aluminum. Would two toolboxes be a good design? I'm not sure I would need a water tank.
    #11
  12. BlitzBike

    BlitzBike LC4 Pilot

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    Yes, two tool boxes is the ticket.
    #12
  13. KTM640Dakar

    KTM640Dakar Motorsick

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    If anyone has drawings of the petcock side of the toolbox? I will start with that one.
    #13
  14. BlitzBike

    BlitzBike LC4 Pilot

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    We need flannys input since he had it all drawn up and figured out at one point.
    Maybe he will loan us his blue prints?
    #14
  15. Mack

    Mack Gone, but never forgotten. RIP, Mack...

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    IIRC, BlownCJ has the drawings Flanny made up.
    #15
  16. Flanny

    Flanny Flanny-it-up!

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    There is a good reason the two-toolbox and/or water container skid plate is expensive. If you want to make it look good, and work right, then the piece becomes very intricate - plain and simple.

    Firstly, cutting all of the pieces out can be spendy. The best way to get this done is with a water jet cutter, but even then, the set-up fees to convert drawings into code is spendy on a small run (ie: <25).

    Secondly, once you have all of your flate peices, there is a LOT of bending to do to get the tool boxes into the right shape.

    Thirdly, it turns out that there is a fair bit of welding to be done to stitch it all together once it is ready for welding.

    Fourthly, the tool-box lids should seal to keep water and crap out, so that implies a further level of quality.

    Finally, the thing is big and heavy at the end of the line, and it costs a lot to ship around.

    One more factor to consider is that the thing needs to be designed, and a prototype made to ensure a good fit. So, right off the bat those costs in time are big, and making the first prototype will be very expensive, since the prototype is a one off.

    Quoting KTim's experience is irrelevant, because firstly he is in England, and secondly making one down at the local shop by some guys who did it as a favour is not the same as preparing a production run of twenty units. When you walk into a shop with fairly complex looking plans, and start talking about small runs, the machinists/fabricators know they are going to be up to they eye-balls in the project so they make sure to get their pricing done right, and to build safety margins into it. The uncertainty becomes reflected in the price.

    Anyway, as sure as the sun will rise, there will be someone who thinks this project can be done inexpensively, and all I can say to that is good luck organizing it all, and more power to 'ya if you can get it done. I would be the first to applaud, becuase I'd like to see it happen. But....I think the bottom line is this: The thing will always turn out to be spendy, and you'll invest a pretty good amount of time figuring that out again for the bizillionth time.

    As indicated above, my plans were sent to BLOWNCJ, so you'd need to contact him to see if he wants to share. Remember though, those plans were never turned into a prototype, so even there, there may need to be significant adjustments made.

    One final thing before I stop the rant. Mike Shelton from poland was able to build the things cheaply, and he was able to sell them for $450 USD I think. I think that if anything, the best bet would be to try to make a bulk purchase through him.

    His e-mail used to be: shelton@wp.pl

    Good luck with the project!
    #16
  17. KTM640Dakar

    KTM640Dakar Motorsick

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    What if you keep it simple and use flat pieces that you can cut with a plasma cutter You could incorperate the front of the box with the side flange that attaches to the OEM skid plate. Then use a lid that has a screw in one corner that you could use as a sliding hinge. It might not be waterproof but it might only cost $100 to make. (per side that is)
    #17
  18. overlandr

    overlandr Dystopist

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    What is it that attracts people to these? Practicality? Rallye Look? Ok so they do give a greater protection to the sides of the engine and also the lowest part of the tank /tap so what do people store in them?? Tools, Water (god forbid) or something else? Please lets know what are your reasons for using/wanting these!

    Cheers
    #18
  19. Surly

    Surly surly adventurer

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    lower CG
    pectcok and tank protection
    #19
  20. G.Kennedy

    G.Kennedy ...

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    I say lower CG also. My recent trip to Baja had me carrying almost 10 of tools on a minimalist trip. All that weight was above the axles. The lower it can be moved the better.

    Secondly, I dropped my bike three times, always to the left. The first thing I would check is the petcock, hoping it had not been sheared off. Some protection would be nice.

    If I had the means, I would buy the factory(sommer) version in a second. Most likely the two tool box version.
    #20