KTM EXC RFS to Street Scrambler

Discussion in 'Some Assembly Required' started by ghostridergary, Dec 3, 2018.

  1. DiggerD

    DiggerD DougFir from SuperDuke Days

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    [​IMG]


    Roland Sands KTM690 rad covers don't look half bad..
    #21
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  2. willmaniac

    willmaniac Adventurer

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    Think he has also done a couple of 4 strokes . Google engineered to slide
    #22
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  3. Trackster12

    Trackster12 Been here awhile

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    The radiators are much easier to deal with on the 690, not much real estate on the EXC chassis. I'm agonizing with that on my project.
    #23
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  4. ghostridergary

    ghostridergary Adventurer

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    So connected up the cooling system using a T piece instead of the thermostat (as per SX) and some judicious slicing of various old hoses

    upload_2019-1-6_16-52-45.png

    upload_2019-1-6_16-53-10.png
    BTW in the meantime I gave the exhaust a couple of coats of this and connected it up.

    upload_2019-1-6_16-55-36.png
    #24
  5. ghostridergary

    ghostridergary Adventurer

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    Also made up the bracket for the tank sides to slide into, using those isolation joints:

    upload_2019-1-6_16-57-40.png

    Bolted this into frame after drilling and tapping - the idea is that the new tank fits without removing the original central tank pillar in case I want to take it back to normal.

    upload_2019-1-6_16-59-27.png
    #25
  6. ghostridergary

    ghostridergary Adventurer

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    Put the tank on to test:

    upload_2019-1-12_21-0-56.png

    Need to spray that cap black (or orange)! Tank pinches the hose on right hand side a bit (nothing too bad) but might try to straighten the outlet to point downwards (as per the left one).

    With seat in place ( a cheap ebay version), overall the rads don't seem to stick out too much

    upload_2019-1-12_21-3-8.png
    #26
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  7. ghostridergary

    ghostridergary Adventurer

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    To get the ADV front wheel to fit I had to make some spacers - basically the EXC hub is 117mm while the ADV one is 108mm. So I took 2 old EXC spacers and cut them down to ~4.5mm each and used them as additional spacers:

    upload_2019-1-12_21-8-36.png

    Thusly fitted..... (note the crappy corroded spokes on those 2004 adventure wheels - probably a rebuild/powder coat when I have some spare cash... )

    upload_2019-1-12_21-10-25.png

    So, from the front with the fork guards fitted to hold the brake hose cable (with "rally" routing) and speedo cable, although not entirely sure about them, and a cleaner way would be nicer (but hose clips looked a bit crap)

    upload_2019-1-12_21-16-30.png
    #27
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  8. NVTS

    NVTS Are you ennen oh eff tee Supporter

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    I would run the speedo cable inside the fork leg next to the brake cable when you're ready for final assembly.
    Looks like fun
    #28
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  9. Gedrog

    Gedrog 1000 mile stare a 1000 stories to tell

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    Just thinking out loud, would it not be possible to drop the radiators by 40-50mm, and lean it forward at an angle to give you more space and and enable you to move the tank further forward, and it sounds like you will be mainly using it on the road, therefore the size of the radiators could potentially be reduced, as the airflow is more constant, whereas the radiators are designed for off-road use, to provide more cooling for slower speeds, and stagnant use.
    #29
  10. ghostridergary

    ghostridergary Adventurer

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    Hi - Thanks for your comments

    Gedrog - thanks for your thoughts - I spent some time trying various combinations of the radiator siting but if you try to tilt them forward you end up with clearance problems at full steering lock and dropping them leads to other frame clearance issues - its all a bit tight there!. The best solution would probably just be smaller custom made (half height) ones so the tank can be moved forward, but I don't have the skills/ contacts/money for that at the moment! Thanks for the idea though.

    So need to decide about mudguard......3 options:

    a) No mudguard as per original :

    [​IMG]

    upload_2019-1-19_15-30-59.png

    b) Low mudguard with integrated fork guards (as per 640 adventures)... need one in black though!

    upload_2019-1-19_15-32-34.png

    c) High mudguard (maybe a supermoto one in black - this is a EXC one chopped down).....

    upload_2019-1-19_15-34-33.png
    #30
  11. ghostridergary

    ghostridergary Adventurer

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    Sorry for the pause.... so made the sub-frame from some rectangular aluminium bar, sheet aluminium, a drill press and some taps.

    upload_2019-2-4_9-32-50.png

    I bolted it together to start with to get the fit right (and I can't weld aluminium but will get someone to do it properly now the fitting is correct) and needed to do some filing around the area (a) where it attached to the frame by the exhaust (b) on the top left fitting to the frame to avoid the petrol tap on the tank.

    upload_2019-2-4_9-38-5.png


    Looks a bit ugly but once its welded I'll tidy it up, spray it black and hide the ugly bits under the seat and side panels!

    upload_2019-2-4_9-40-13.png
    #31
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  12. Trackster12

    Trackster12 Been here awhile

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    I like the low, black will look good. I have been thinking of a Versys front fender for my ECX.
    #32
  13. ghostridergary

    ghostridergary Adventurer

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    Hi Trackster

    Thanks - I think I agree - unfortunately that is the expensive option! I've got an orange low fender for a 640 adventure - might test to see how that looks.

    Sorry for the lack of progress - working on my 640 Adventure for a trip - but hope to get rear suspension lowered next week and subframe welded up.

    Obtained a cheap, shorty exhaust from £20 from ebay though:

    upload_2019-2-16_9-32-59.png

    upload_2019-2-16_9-33-52.png

    #33
  14. ghostridergary

    ghostridergary Adventurer

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    Finally got the subframe welded up, primed and sprayed

    upload_2019-2-27_11-36-28.png
    And shortened the rear shock with a 12mm internal spacer - usual length is 403mm,now ~390mm

    upload_2019-2-27_11-37-43.png
    Now to fit it all back together......
    #34
  15. ghostridergary

    ghostridergary Adventurer

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    Sorry for the lack of progress - been in Morocco for the last 3 weeks giving the 640 a run out!

    upload_2019-3-30_8-3-19.png

    Hopefully get back and finish this in the next few weeks......
    #35
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  16. Bt10

    Bt10 Been here awhile

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    A lot more work I know, but I can envision notching the tank to move forward over the rads. Looking good.
    #36
  17. ghostridergary

    ghostridergary Adventurer

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    Attached Files:

    #37
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  18. ghostridergary

    ghostridergary Adventurer

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    Test fitted tank and seat (both from ebay):

    upload_2019-4-6_8-49-5.png



    upload_2019-4-6_8-49-25.png

    upload_2019-4-6_8-49-54.png


    Need to:

    - Respray the tank
    - Sort out some side panels
    - Do something about hiding that wiring behind the headlamp!
    - Decide on front mudguard options (and maybe refit bashplate)

    Then get out for the summer......
    #38
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  19. tinwelp

    tinwelp Professional Idiot

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    It looks kind of stumpy... but I think it would grow on me! It's certainly different.

    Question though: will you be ok with the rear suspension fully compressed? It looks as if you'll crash the tyre into the licence plate and then the plate on the subframe.

    Cheers... Paul
    #39
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  20. LC8TY

    LC8TY must......find........fuel

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    nice work

    Check out Aliexpress and search for "scrambler" or "scrambler side plate" and you'll find what your looking for, and much more.
    #40
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