Tuareg Rallye 2013 - The Next Adventure

Discussion in 'Racing' started by schattat, Feb 9, 2013.

  1. schattat

    schattat Long timer

    Joined:
    May 18, 2008
    Oddometer:
    1,447
    Location:
    Frankfurt am Main, Germany
    Hi gang,

    It's been a while since my last big adventure in Abu Dhabi in 2010. Since then I have completed my school studies, got into university and setup and expanded my RNS business for TripMasters and CompassRepeaters as many of you are aware of. Due to having so much going on I haven't had the time to actually race much. There was also the incident when my bike was knicked in July after a trail ride through France. Fortunately, the coppers were able to retreve the bike miraculously without any damage whatsoever (apart from worn down tires).

    Anyway back on topic, this thread is about my preparation towards the Tuareg rallye in March. The event as many of you are familiar with was always held in Morocco in the past bu has since moved to Tunisia for the first time this year. The start will take palce in Douz, an Oasis in the very south pretty much bordering the Sahara desert. I will be joined by some good friends, Edward Taylor and Guillaume Martens (2nd in the Africa Race). There will of course be many ADVers joing including LukasM, GSNorCal, Neduro just to name a few. Yet again, I will be using my trusty WR450F and here is the build up that many of you fancy so much :evil:

    To start with, the bike is torn down to a nacked frame, which is repainted (matt blue):
    [​IMG][​IMG]

    Instead of designing my nav tower like in the past, I have opted to use a finished one from a KTM rallye, thanks to the help of the factory mechanics for helping me source some of the parts:
    [​IMG][​IMG]

    [​IMG]

    The nice thing about the setup is that it's wide, which allows one to mount more crap on to :D
    [​IMG]
    The frame support is the same as in the past, but needs to be modified to accomodate the KTM forged supports (very nicely made):
    [​IMG][​IMG]

    I lathed some spacers so the 2 stainless steel mounts wouldn't be pressed together under the tension of the 2 screws:
    [​IMG][​IMG]

    The nice forged parts have spaces for the hex nuts instead of having a thread inside themselves, clever!
    [​IMG][​IMG]

    Post tower for the steering damper before the triple clamps are installed:
    [​IMG][​IMG]

    Rare to get hold of, original Yamaha factory rear hub with a cushion drive, less strain on the gear box:
    [​IMG][​IMG]

    Nice bling, 49T stealth sprocket:
    [​IMG][​IMG]
    [​IMG]
    #1
  2. schattat

    schattat Long timer

    Joined:
    May 18, 2008
    Oddometer:
    1,447
    Location:
    Frankfurt am Main, Germany
    Next custom mod on the list was something unique. I always liked the KTM footpegs on the rallye replicas, not too wide, but very long. Very nice with my size 47/12 boots:
    [​IMG][​IMG]

    A comparison, custom vs. stock:
    [​IMG][​IMG]

    I wasn't sure whether they would fit (why would they really?), but judging from many pictures I came to the conclusion that the folding angle of about 45° and the width to fit on to the frame were pretty similar to the stock WR pegs:
    [​IMG][​IMG]

    How right I was :lol3 Even the 10mm bolt from the KTM fits perfectly, both in diameter and length!
    [​IMG][​IMG]

    First hold up was the width for the mount. KTM pegs width was 30mm, the space in the frame was 29mm (odd uneven number, not very Japanese-like):
    [​IMG][​IMG]

    Not to worry, just grind down a bit on the pegs on each side and they slip in perfectly:
    [​IMG][​IMG]

    I found the angle to which the pegs were tilted to the back to be too much, so I grinded more on the bottom of the pegs where they hit the frame:
    [​IMG]
    [​IMG]
    #2
  3. LukasM

    LukasM Long timer

    Joined:
    Nov 15, 2006
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    Location:
    On a RTW ride - next stop USA!
    :lurk:thumb
    #3
  4. Muecke

    Muecke Adventurer

    Joined:
    Jan 18, 2010
    Oddometer:
    75
    Location:
    Germany
    nice tony so there ist One more reason to visit you in short time . bye muecke
    #4
  5. tehdutchie

    tehdutchie Long timer

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    Jun 15, 2009
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    1,906
    Location:
    Amsterdam or on Twitter @antal
    Goed bezig!
    #5
  6. doyle

    doyle RallyRaidReview-ing

    Joined:
    Jan 14, 2004
    Oddometer:
    24,001
    Location:
    Off Piste
    Looks good.
    #6
  7. Hayduke

    Hayduke ///SAFETY THIRD/// Super Moderator

    Joined:
    Jun 8, 2004
    Oddometer:
    44,311
    Location:
    Salida, coloRADo
    :lurk
    #7
  8. K_N_Fodder

    K_N_Fodder Long timer

    Joined:
    Nov 1, 2006
    Oddometer:
    1,069
    Location:
    Ten Sleep, WY
    Hmmmm Tuareg F5?? :)
    #8
  9. schattat

    schattat Long timer

    Joined:
    May 18, 2008
    Oddometer:
    1,447
    Location:
    Frankfurt am Main, Germany
    Next step was to fabricate the new stabiliser bars between the two nav tower plates. I couldn't use the ones out of the KTM catalogue since the spacing between the plates was a little smaller than stock, but no problem lathing them quickly:
    <!--[if gte mso 9]><xml> <o:OfficeDocumentSettings> <o:AllowPNG/> </o:OfficeDocumentSettings> </xml><![endif]-->[​IMG]

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Name="Medium Grid 1 Accent 6"/> <w:LsdException Locked="false" Priority="68" SemiHidden="false" UnhideWhenUsed="false" Name="Medium Grid 2 Accent 6"/> <w:LsdException Locked="false" Priority="69" SemiHidden="false" UnhideWhenUsed="false" Name="Medium Grid 3 Accent 6"/> <w:LsdException Locked="false" Priority="70" SemiHidden="false" UnhideWhenUsed="false" Name="Dark List Accent 6"/> <w:LsdException Locked="false" Priority="71" SemiHidden="false" UnhideWhenUsed="false" Name="Colorful Shading Accent 6"/> <w:LsdException Locked="false" Priority="72" SemiHidden="false" UnhideWhenUsed="false" Name="Colorful List Accent 6"/> <w:LsdException Locked="false" Priority="73" SemiHidden="false" UnhideWhenUsed="false" Name="Colorful Grid Accent 6"/> <w:LsdException Locked="false" Priority="19" SemiHidden="false" UnhideWhenUsed="false" QFormat="true" Name="Subtle Emphasis"/> <w:LsdException Locked="false" Priority="21" SemiHidden="false" UnhideWhenUsed="false" QFormat="true" Name="Intense Emphasis"/> <w:LsdException Locked="false" Priority="31" SemiHidden="false" UnhideWhenUsed="false" QFormat="true" Name="Subtle Reference"/> <w:LsdException Locked="false" Priority="32" SemiHidden="false" UnhideWhenUsed="false" QFormat="true" Name="Intense Reference"/> <w:LsdException Locked="false" Priority="33" SemiHidden="false" UnhideWhenUsed="false" QFormat="true" Name="Book Title"/> <w:LsdException Locked="false" Priority="37" Name="Bibliography"/> <w:LsdException Locked="false" Priority="39" QFormat="true" Name="TOC Heading"/> </w:LatentStyles> </xml><![endif]--><!--[if gte mso 10]> <style> /* Style Definitions */ table.MsoNormalTable {mso-style-name:"Table Normal"; mso-tstyle-rowband-size:0; mso-tstyle-colband-size:0; mso-style-noshow:yes; mso-style-priority:99; mso-style-parent:""; mso-padding-alt:0cm 5.4pt 0cm 5.4pt; mso-para-margin:0cm; mso-para-margin-bottom:.0001pt; mso-pagination:widow-orphan; font-size:11.0pt; font-family:"Calibri","sans-serif"; mso-ascii-font-family:Calibri; mso-ascii-theme-font:minor-latin; mso-hansi-font-family:Calibri; mso-hansi-theme-font:minor-latin; mso-fareast-language:EN-US;} </style> <![endif]-->Same goes for the rubber mounts for the roadbook support plate, had to get different height model and place washers to fit them correctly:
    [​IMG]

    [​IMG]

    [​IMG]

    Good fit now (450RR plate):
    [​IMG]

    Added control lights:
    [​IMG]

    As for headlights, I had a look around and finally came around to getting some LEDs ones. I chose the one sold my ADVmonster, very nice units and SUPER bright. Had to fabricate some spacers tohave the correctly fit the width to fit the fairing later:
    [​IMG]

    [​IMG]

    First fitting attempt:
    [​IMG]

    [​IMG]

    Final fit:
    [​IMG]

    Let there be light:
    [​IMG]

    [​IMG]

    Excuse the messy table:
    [​IMG]

    One problem that did occur with the forged alloy parts from KTm was the steering angle was to large. Instead of the bottom of the triple clamps stopping he turning angle by hitting the stopper on the frame, the forks would do the job. Here you can see the space missing when the forks touched the forged parts:
    [​IMG]

    [​IMG]

    I solved this by drilling holes into the stoppers on the bottom clamps and fitting some screws inside, therefore limiting the steering angle a tad. Similar principle to what many bikes have to adjust the steering angle. Unfortunately these Japanese MX derived bikes don't have that. Pics to follow!
    #9
  10. schattat

    schattat Long timer

    Joined:
    May 18, 2008
    Oddometer:
    1,447
    Location:
    Frankfurt am Main, Germany
    Here some additional parts installed.

    Öhlins rear shock with harder spring rate, borrowed from dad for the event:
    [​IMG]

    Clutch cover protection (the walls are very thin). Just to be on the safe side:
    [​IMG]

    Tall bar risers:
    [​IMG]

    ProGrip 786 rallye grips:
    [​IMG]

    Motomaster 270mm disc adapter. With some careful geometry I drilled and tapped two M8 holes to fit the sensors of the TripMaster:
    [​IMG]

    Front mounts to fit the bash plate (original Yamaha rallye kit parts). Again, borrowed from dad. I was planning on designing and fabricating my own one. The space between these two parts is big enough to make a compartment. Lack of time means I will have to do it sometime later:
    [​IMG]
    #10
  11. Deadly99

    Deadly99 Fast and Far

    Joined:
    Apr 8, 2008
    Oddometer:
    10,190
    Location:
    Merrickville, Canada
    Looking good :thumb




    :lurk
    #11
  12. 640 Armageddon

    640 Armageddon -oo-

    Joined:
    Mar 4, 2009
    Oddometer:
    2,885
    Location:
    Greece
    Subscribed :wings

    Tony, a word of caution with the lights, I have used the lights from ADVmonster as well, they are indeed very bright and the setup was similar.

    [​IMG]

    Having used the normal light supports first, they cracked on my first ride. I know the 640 vibrates a lot more than the Yamaha but better safe than sorry. John from ADVmonster sells also heavy duty supports but they are easy to manufacture from 2mm SS plates ...

    Looking very good and the KTM tower looks :eek1

    D.
    #12
  13. Brodovitch

    Brodovitch Team ⌘R

    Joined:
    Nov 15, 2010
    Oddometer:
    3,171
    Location:
    Athens, Greece
    Have to agree with Dimitri on the light supports, the Raid Designs have a similar design (might even be identical), and a friend's cracked in the 24H race a couple of months ago...
    #13
  14. tehdutchie

    tehdutchie Long timer

    Joined:
    Jun 15, 2009
    Oddometer:
    1,906
    Location:
    Amsterdam or on Twitter @antal
    +1, although I havent used them (yet), the mounts sure do look flimsy and with one bolt only..
    #14
  15. schattat

    schattat Long timer

    Joined:
    May 18, 2008
    Oddometer:
    1,447
    Location:
    Frankfurt am Main, Germany
    Thanks dudes, I will look into the bracket issue!
    #15
  16. Mudguts

    Mudguts when in doubt GAS IT

    Joined:
    Jan 16, 2006
    Oddometer:
    2,154
    Location:
    Some were in , lostralia
    Love your work Tony it's coming along , you will have it insisted before I finish mine ,I only have exhaust and bash plate to go ,
    #16
  17. Muecke

    Muecke Adventurer

    Joined:
    Jan 18, 2010
    Oddometer:
    75
    Location:
    Germany
    can you give me a link where to see technical data of the light and where to buy?
    #17
  18. 640 Armageddon

    640 Armageddon -oo-

    Joined:
    Mar 4, 2009
    Oddometer:
    2,885
    Location:
    Greece
    #18
  19. Muecke

    Muecke Adventurer

    Joined:
    Jan 18, 2010
    Oddometer:
    75
    Location:
    Germany
    Thanks
    #19
  20. PackMule

    PackMule love what you do Super Moderator

    Joined:
    Aug 8, 2005
    Oddometer:
    19,485
    Location:
    New Hampshah
    Have fun, Tony! :beer
    #20