ktm 520exc project

Discussion in 'Thumpers' started by DRjoe, Mar 6, 2010.

  1. DRjoe

    DRjoe Long timer

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    Ok so some may be familiar with the other small project that i have going at the moment.
    Basically i was altering a dr650 with the goal being a dual sport bike that i could use in my first rally but the build has been delayed because of paper work and the rally starts on the 3rd of April and its a 15 hour ride away from me.

    I bought an 01 ktm 520exc a few weeks ago to replace my tired wr250f and i was just going to keep the bike for dirty work only but my hand has been forced and i have to make it in to a rally bike that can do long highway stretches.

    This is the bike when i bought it
    [​IMG]

    Giving it a clean
    [​IMG]

    It came with new excel rims, polisport head light, asv folding levers, bash plate, flash looking gear lever, huge foot pegs, pro circuit pipe, nomad rear tank and loads of other little bits of bling.

    To get it registered it needed: brake discs, pads, indicators, horn tail light and a side stand.

    What it needs for the race is: road book, trip meters, cush drive rear wheel, two sets of tires (one set to get me there and back one set to race on), more fuel capacity, comfy seat and racks (to carry all my camping gear, tires and spares down to the race).

    What i would like to put on it: Oil cooler (there are a few different views on if it needs a cooler), quieter exhaust, fairing and a proper nav tower mounted of the frame not the bars.

    I need to get this built in two weeks so that it gives me time to test the bike plus ride down to the race.

    What do you think my chances are:lol3

    Ok i'm off to the shed to make a rear fuel tank because the one that came with it sits on the rear guard and i don't like that idea.
    #1
  2. dentvet

    dentvet Long timer

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    2 weeks? yes we can

    i kind of like the bolted plate method that dylandr used on his fairing/tower strut. i wonder if it would work on a ktm?
    #2
  3. LukasM

    LukasM Long timer

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    Now that I'm a bit frustrated with the hole engine swap story I am going to build up an RFS rally bike instead myself. I have been doing some reading on the potential issues to watch out for, if you don't think you know it all already I'll write something up for you tomorrow. Off to get some beauty sleep... not that it's gonna help much! :deal
    #3
  4. DRjoe

    DRjoe Long timer

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    Yo no me Lukas I know sweet f all so any info you have would be graetly appreciated.

    I'll post some updates to night with pictures for all that cant be bothered reading.
    #4
  5. DRjoe

    DRjoe Long timer

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    I made some mounting plates for the my dr650 a while ago so i think i'll do the same again and use the tower and lights that I have already made.

    here are the brackets
    [​IMG]

    and here they are bolted to the big girl
    [​IMG]
    #5
  6. dentvet

    dentvet Long timer

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    :ear
    #6
  7. LukasM

    LukasM Long timer

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    If you haven't seen it yet, this thread has some great info:

    http://www.advrider.com/forums/showthread.php?t=540417

    I will have to add some stuff but this I think this should be a good start:

    #7
  8. DRjoe

    DRjoe Long timer

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    Thanks for that Lukas. I never thought that the carb vent pipes would actually let crap in to the motor I'll make a little filter for them.

    I started fitting the rear wheel of the dr650 the other day. The dr wheel is a surprisingly good fit, the axle's are the same size and now i have machined the left spacer down to line the sprocket up it also centers the wheel. I have to turn the dr disc down to fit the caliper and pack it out from the hub by a few mm I'll be using a very technical method that involves washers between the hub and disc to do that :lol3

    I have also started work on the rear tank all that is left to do is fit a fuel tap and weld on a filler neck I think it will hold about 5.5lt.
    And yes I know that i could have bought a plastic one but it was cheaper and quicker for me to make one rather than order one from the US.

    The local upholstery shop also sorted my seat for me, They made it wider at the back and recovered it in suede with gripper panels at the front. I have to say it is very comfy and the suede works great when riding off road and even in the wet it worked well.

    Here are some pics pics of the tank and seat.

    Space available for a tank
    [​IMG]
    [​IMG]

    The basic shape of the tank
    [​IMG]

    The parts for the tank all ready for welding together
    [​IMG]

    Finished (almost)
    [​IMG]
    [​IMG]
    [​IMG]

    I had to leave a cut out for the chain when the suspension is a at full travel
    [​IMG]

    Seat and side panel fitted
    [​IMG]
    [​IMG]

    The seat is about 50% wider he also so made the extensions just slightly softer than the original foam
    [​IMG]

    I'll hopefully get the wheel fitted and the tank finished tomorrow and then I can move on to the nav gear.
    #8
  9. header

    header Chris

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    :lurk
    #9
  10. DRjoe

    DRjoe Long timer

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    It always takes me ages to type anything and then it make no bloody sense so f#$k words.
    I'm sure you'll get the general idea from the pics.

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]
    #10
  11. DRjoe

    DRjoe Long timer

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    Ok so I do stupid stuff all the time and I always get away with it but unfortunately tonight I didn't get away with being stupid.

    I type this whilst suffering smoke inhalation yes ladies and gentlemen I set my bike on fire :lol3:lol3:lol3.

    I was waiting for the resin to dry on the fairing so i could get on with the next stage and me being an impatient bastard mixed up a hot mix of resin and put another layer on the fairing but that seemed to dry no quicker so I thought well its quite cool maybe i should get the blow torch out and warm things up.
    I new that the wet resin is very flammable but yet a still carefully waved the torch in front of it to try and speed the curing process but again i'm an impatient bastard so I kept putting torch closer and closer until woomf she went up.

    Well I did manage to rip the fairing of the bike before the bike went up but unfortunately the fairing is no more.

    Oops.

    :lol3:lol3
    #11
  12. V8R

    V8R Been here awhile

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    aweome work and pics mate, i wish i could fabricate shit half as well...




    oh, and lol with the latest post, sometimes slower is quicker ;)
    #12
  13. header

    header Chris

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    :rofl

    That fairing was looking sweet too! Oh well, cant get it back now.

    Keep up the good work and dont worry about your english, its plenty good enough.

    Enjoying the build.
    #13
  14. mmitchell57

    mmitchell57 Vulcan Halfbreed

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    Awesome. Considering your work on the DR, this one should come out awesome. I think 2 weeks should be good for you, considering you've already done all this one recently.

    :lurk
    #14
  15. DRjoe

    DRjoe Long timer

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    Any one can fabricate stuff it's just you need the time and a few tools to do it.
    I've got what i would say is the bare minimum you could get away with. A vice, grinder, drill, hammer and a welder. You could do all this stuff without the welder but it would be a pain in the arse getting everything welded up by someone else.

    And your not wrong about slower is quicker.
    #15
  16. DRjoe

    DRjoe Long timer

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    Ah but the second one will be better.
    #16
  17. DRjoe

    DRjoe Long timer

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    Yea well the lights and nav tower are stolen from the dr project all i had to do was make a new road book mounting plate because the other one got KO in a little fall i had.

    I'm hoping to get a rough fairing done today and then go riding tomorrow to test everything and hopefully I'll get a chance to set the suspender up to.

    Ok i better get back to the garrage
    #17
  18. GR0NK

    GR0NK Got some screws loose!

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    Looking good. Don't know how I missed this thread for 5 days! :huh


    Sean :bmwrider
    #18
  19. GR0NK

    GR0NK Got some screws loose!

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    My friend built his 530 into something similar.

    Didn't make his own fairing or aux. fuel tank however.

    [​IMG]

    [​IMG]

    [​IMG]



    Sean :bmwrider
    #19
  20. G600

    G600 Been here awhile

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    Sean, did your friend strengthen the subframe? If so , do you know how?
    #20