Rally Raid Engineering - Discounts for helping to develop new Carbon/Kevlar parts!

Discussion in 'OZ Vendors & Flea Market' started by michael1968, Sep 4, 2013.

  1. michael1968

    michael1968 Long timer

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    Hello fellow Oz inmates,

    As some of you know I’ve been making various carbon/kevlar parts for off road bikes for the past year or so now, I’ve started a small business called Rally Raid Engineering (rallyraid.weebly.com). My most popular item has been Tank Guards for the KTM 640 Adventure, I’ve been flat out making these for the last few months but now finally have some time to develop new products (this isn’t my ‘real’ job unfortunately).

    This is where you guys come in;
    I’m looking for people who own dirt/adventure/rally bikes to let me use their bikes (or parts of their bikes) to develop new parts from. I’m based in Newcastle so it’s obviously easiest if you are somewhere in the area but arrangements can be made. I’m looking for fairly popular bikes, eg. EXC/690/950/990, DR/DRZ/RM, CRF, YZ/WR, F560/F800 etc etc etc. The process usually takes a few weeks, I’d need the bike or parts for a few days to a few weeks depending on the complexity of what I’m making. I'd be looking for your feedback on the fit/form/function of the part.

    I’m open to ideas but I’m looking at developing the following;
    -Bashplates including toolbox/storage
    -Fairings to mount to large tanks (Safari etc)
    -Rally style fuel tanks (think 450RR)
    -Sub-frame fuel tanks (to replace your stock subframe)
    -other smaller parts including Case (clutch/alt) Guards, Tank Guards, Fork Guards

    What’s in it for you?
    If you generously lend me your pride and joy I will sell the parts I develop from it to you for a heavily discounted price. The final price depends what I think the commercial demand for the part is eg. I can make a Bashplate for an EXC or other popular model for you at about 40% of what I would usually charge.

    What’s in it for me?
    I sell copies of the parts I develop to others to support my motorcycling habit. I try to price my products reasonably, the price of each part is determined from the cost of the materials and the time they take to make, not what I think someone will pay.

    Please reply on this thread, PM me or contact me via my website if this sounds like something you are interested in.

    I’ll be posting details and pictures of any new products in this thread also.

    Please check out my thread on the 640 Adventure Carbon/Kevlar Tank, Petcock, Case and Frame Guards or my website if you would like to see some of my work, some pictures of my recent work are also below.

    All of the parts I make are vacuum bagged using epoxy as the matrix with carbon and kevlar as the reinforcement. Vacuum bagging ensures the highest strength to weight ratio of the parts, you will be surprised at the strength and light weight of the parts.

    Cheers,
    Michael

    LC4 Case Guards
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    640 Adventure Tank Guards
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    640 Adventure Tank Guards with Petcock Guard
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    640 Adventure Frame Guards
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    #1
  2. OldDog

    OldDog aka Hugh Jarse

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    Yo Michael, If you want to develop stuff for the 950 990 range of bikes, I am currently wrecking a 950, rather than sell off the tanks etc now, I could lend em to you for making moulds etc first. I can sell my tanks and stuff when you're finished with em. Just a thought
    I also might be looking for some custom made stuff at some stage if yer interested?

    Cheers

    Bill
    #2
  3. michael1968

    michael1968 Long timer

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    Hi Bill,

    Thanks for the offer!

    Does that 950 have a low front fender? I'd be interested in making a copy of that and adapting it to other bikes.

    I'll be PM'ing you shortly about the tanks etc.

    Always interested in making custom stuff!

    Cheers,
    Michael
    #3
  4. michael1968

    michael1968 Long timer

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    Thanks to rjf for the loan of his KTM 640 Rear Rally Tanks, I'm going to try to make a copy of them in carbon/Kevlar, it's a pretty complicated shape so might be a little tricky.

    If all goes well I'll be looking for someone with a 640 in the next few months so that I can adapt the tanks to fit a standard subframe.

    Cheers,
    Michael

    [​IMG]
    #4
  5. watagans300exc

    watagans300exc Been here awhile

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    Hi Michael,

    I'd be very interested in a set of those tanks if you need a test bike....... I am on the central coast and drive past Newcastle almost weekly. I haver an 07-625 SXC I'd like to put the tanks on.

    Cheers,

    Tony.
    #5
  6. michael1968

    michael1968 Long timer

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    Excellent, I'll be in touch when I have the proto ready!
    #6
  7. Pete640

    Pete640 Long timer

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    There is a bit of work to get those tanks to fit up onto a 640A subframe. Think exhaust, hangers, seat and rear lights. I have a set if someone wants to give them a go?
    #7
  8. 640 Armageddon

    640 Armageddon Do or Do Not. There is no try.

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    Tried to adapt at some point to mine a set I got from Germany. Time consuming and when I run out of time I sold them back :D

    I think that this type of tanks will raise the center of gravity of the bike by a fair amount and that is why companies (and KTM in their next 660) put the tanks lower

    I am talking about these ones,

    [​IMG]

    [​IMG]

    I know that the above tanks need a fair amount of frame change. So. Anybody to pop in for an aftermarket subframe as well ? :D
    #8
  9. Pete640

    Pete640 Long timer

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    Yes they are the later tanks. The 640rr tanks I have hold the fuel even higher and across the top of the subframe.
    Evolution has taught KTM well!
    #9
  10. 640 Armageddon

    640 Armageddon Do or Do Not. There is no try.

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    Even higher? My God... a rucksack tank? :evil:evil
    #10
  11. Pete640

    Pete640 Long timer

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    Worse. Helmet fuel tank. Just need a dry break connector
    But it does drain well!!!
    #11
  12. michael1968

    michael1968 Long timer

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    Thanks for the tips guys, after talking to a few people I've decided to make a modified version of the ones I posted a pic of, they'll kind of be a cross between those and the later 640 rallye tanks. They'll still loop up over the rear fender (and likely pick up the rack mount holes) but will extend down to the lower subframe mount and also lower at the rear.

    I'm planning on making them fit with no mods to the subframe or exhaust but we'll see if that's possible, I'm mostly worried about the exhaust...

    I've also got a few other things in the works (or soon to be when the parts turn up), 640 adv tall fairing, DRZ case guards and one other 'special' fairing.

    Cheers,
    Michael
    #12
  13. tHEtREV

    tHEtREV Captain Awesome... tEAM iDIOT.

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    Things to take into account with mounting the pre97 rallye tanks (and hopefully things that will be rectified by Michael)

    All the mounting points need to be welded to the subframe, stock exhaust won't fit (I use a FMF Q4 and it sits close, I think it is the SX that is needed).

    Airbox access is a bitch because the left tank needs to be removed, and also the a new air box cover needs to be made.

    Subframe needs bracing, but mounting tabs can double as bracing.:wink:

    You do notice the extra fuel weight when you first take off, but I don't notice after the initial shock of that much weight.

    Some people say they are hopeless in soft sandy woops because the tanks hit your calves, but I found them like Stegz pegz.:D

    And finally, it is a shitload of fuel, I recon most people would need it once a year if that.

    Love mine though, and I'm keeping them.:lol3
    #13
  14. 640 Armageddon

    640 Armageddon Do or Do Not. There is no try.

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    I am following that Michael :D

    The airobox will be tricky but may be a modified cover were you just take the seat off to remove it would be better? :ear
    It could be done with the side tank but I think the mold would be over complicated.

    +1 on the subframe, it tend to crack as it is, never mind if you put triplets and higher loads....

    Another point would be the access to the rear shock as the piggy is on the side.

    MIchael you are talking about two tanks right? May be that is a way better option as riders may be able to buy only the right tank for example should they want to have easy access to the air filter and shock. Just a thought... Then the hardcore ones can go on and modify things :D
    #14
  15. Pete640

    Pete640 Long timer

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    Ill he very interested to see how you go about it.
    But thinking of ur target audience how many will need extra range on a bike that already does 500 km to a tank full?
    #15
  16. michael1968

    michael1968 Long timer

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    That's what I thought but I've been getting quite a few enquires on my website about it.

    It'll also fit the SXC which needs the extra range more than the adventure.
    #16
  17. 640 Armageddon

    640 Armageddon Do or Do Not. There is no try.

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    You can never have too much petrol :D

    It will be interesting to do the 24hrs Rally Raid with all tanks full in one go :evil
    #17
  18. tHEtREV

    tHEtREV Captain Awesome... tEAM iDIOT.

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    Oh and I forgot to mention the original seat leaves a massive gap between the top of the tank and bottom of the seat, older rear guard has to be used and the rear cross piece thingy at the back of the subframe that the original guard attaches to needs to be cut out and replaced by a piece of flat bar.
    #18
  19. michael1968

    michael1968 Long timer

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    Thanks Trev, looks like I'll be using less of the original tanks shape than I thought!

    I think it'll still be worthwhile to start with a mould off them though, it's usually easier to start with something than nothing.
    #19
  20. michael1968

    michael1968 Long timer

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    The plugs are getting there;

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    #20