(Updated 2.25.18)Machined some fork guard brackets today

Discussion in 'Hard. Core. (1090/1190/1290)' started by MVmann, Jun 27, 2016.

  1. MVmann

    MVmann Made In America (with German parts)

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    I did the high mount fender a few months ago and finally got around to machining some brackets today. I don't really care for the zip tie on the forks guards so.....
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    don't mind the hardware holding them onto the forks (stole some off the bodywork) haven't had a chance to go to the hardware store.
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    Unfortunately the way the fork bottom itself is cast it makes it hard to get them much tighter (closer) to the fork. Ver 2.0 I can move closer by approx .25
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    The right side guard sits a little further away than the left as it was designed for clearance to the disk brake. I will compensate for that on the next set, and also offset the flat in the first picture back as much as I can to get the guards closer. The guards are from a KTM SX85. Brackets are Aluminum 6061 T651. Let me know what you think.
    #1
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  2. Lutarious

    Lutarious Renaissance Man

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    Ill buy a set of those right away. Paypal okay?
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  3. MX Engineer

    MX Engineer MX Racer

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    Awesome! I want a set too!

    Do they make white fork guards for this KTM85?
    #3
  4. Barekat

    Barekat Looking to get dirty Supporter

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    Looks interesting for a mount. I'd be concerned a hard hit would push that aluminum bracket right into the fork tube. :arg
    #4
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  5. MX Engineer

    MX Engineer MX Racer

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    This hard of a hit would first have to bend the cast bracket on the "knuckle". Then we will have much bigger problems!
    #5
  6. Barekat

    Barekat Looking to get dirty Supporter

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    Good point. I like the clean look of the high fender.
    #6
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  7. Duane1969

    Duane1969 Been here awhile

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    Very...........very nice! I'd like a set too when available! :thumbup:beer
    #7
  8. MX Engineer

    MX Engineer MX Racer

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    I have bought a high fender kit, and I am just waiting to find a solution for the fork guards before I bolt it on. Can't wait!

    I have a question that I need to resolve in my head though. I've been curious if high fenders have some sort of a disadvantage. Will I ever come to miss the low fender, like on a rainy day, for example? Perhaps my worries would only apply if I had no windshield...
    #8
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  9. MVmann

    MVmann Made In America (with German parts)

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    I will be changing a few things this weekend to get a slightly better fit. I have to order some more material and figure out a price, I will keep everyone up to date.

    Sent from my SAMSUNG-SM-G900A using Tapatalk
    #9
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  10. Duane1969

    Duane1969 Been here awhile

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    Thanks!
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  11. sati8d

    sati8d REALLY?? Supporter

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    Me too

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  12. Lutarious

    Lutarious Renaissance Man

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    Seems like you could move them in to center properly on the fork tubes and maybe cut away a little bit of the plastic to make it clear the brake disk. Anyway, I really like this approach. Hope you get some done in time for our big trip to South Dakota this summer.
    #12
  13. fishrman

    fishrman Been here awhile

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    I'm in :y0!
    #13
  14. MVmann

    MVmann Made In America (with German parts)

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    Update:
    I had some time this afternoon and machined Ver.2.0 I wanted to get the guards to center better on the forks and also move them back around the forks further. Here is what I have so far.. Ver.2.0 on the right
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    The left fork guard will require slight trimming of approx. 1/8 of an inch to clear the disk bolts. The right side guard is already trimmed to clear the brakes on the KTM SX85.
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    This side pic is of the original design, you can see how far the fork guard is away from the fork.
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    This pic is from Ver 2.0 it wraps around the fork better but still not as closely as I would like. Unfortunately this is as far back as I can get it, the design of the fork makes it difficult.
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    I have a little more work to do on the design, just some more clearance on the back side where it contacts the cast "fingers" for the original fender.
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    I should be able to make some changes this weekend and hopefully post up with a final product. I am thinking of $50 per set shipped to conus, this will include 4 socket cap or button head Allen bolts to mount the brackets to the bike. I am still trying to source some bolts for the fork guards themselves (69008021160 SPECIAL SCREW M5X12) as KTM wants $$ as does most other places $2.69 a piece. The easiest thing to do would be to use the existing shoulder bolts that came off of the original fender (you should have 6 of them).
    The brackets will come in the raw as I don't have access to anodizing. They are made from 6061 T651 which is very corrosion resistant and would be fine un-coated in most environments.
    #14
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  15. MVmann

    MVmann Made In America (with German parts)

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    Final Ver.2.1 is complete! bolts right up with no fitment issues.
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    Looking down onto the fork guards.
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    I am waiting on material now, hopefully middle of next week. I should be able to start running them next weekend. I will be doing twenty sets for the first run. I will keep everyone posted.
    #15
  16. michdave

    michdave Been here awhile

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    Thank you for building those. I haven't committed to a high fender yet, but seeing so many folks zip-tying those things in place made me cringe. LOL.

    That's a nice finished look now. Well done! If I end up going that route, I'll definitely be contacting you if you choose to make more and sell them.

    Nice work and thanks for sharing!


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    #16
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  17. sati8d

    sati8d REALLY?? Supporter

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    Dude that is really nice work!

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    #17
  18. Duane1969

    Duane1969 Been here awhile

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    ^^^^^^^^^^^^^^^^

    What he said!!!!!:thumbup
    #18
  19. Dirtroadsinms

    Dirtroadsinms Been here awhile

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    I'm in for a set too, just let me know when. Excellent craftsmanship
    #19
  20. TDye82

    TDye82 Adventurer

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    Nice work! I would like to put my name on the list for a set.
    #20