Another DIY Rally Bike

[john_aero]

Ok so got boared this week, sold my fairings dash etc and fitting rally fairing that got yesterday in post.

be using std forks initally but will be doing same as i did on my f650 daakr, fitting kayaba usd forks. this time i will be using 2 left legs (bit work here) to keep the twin disk setup on the africa twin.

Have to get new headlihgt, new dash. then machine up new fairing stem to hold lights and top of fairing.

will make it so i can fit the dash, gps and in future a elec roadbook.

Then when done i will work on the forks at the side.

have machine up 2 new calliper hangars, new axel and a new top clan stem to take the xrv750 headstock bearings

 

[Buttso]

Wow.. Great project... Looking forward to seeing it done ...

 

[john_aero]

i like rally bikes so hence why i like building replics of them

that and i nearly rather working on them as much as riding them

 

[exit speed]

Looks great- a desert racer look-

 

[john_aero]

Looks great- a desert racer look-

http://www.boano.com/factory_moto.asp

my inspiration

 

[earthmover]

Oooh, that fairing looks very nice! Keep posting as you go, would like to see how it goes on.
Do you actually need the twin discs? I took one off my KTM 640, and still had more than enough stopping power. Just a thought.
Mark

 

[john_aero]

Oooh, that fairing looks very nice! Keep posting as you go, would like to see how it goes on.
Do you actually need the twin discs? I took one off my KTM 640, and still had more than enough stopping power. Just a thought.
Mark

cost, if i could get a set wp forks with wheel and calliper i would but dont have the cash to spend for what they are making. most complete front ends making stupid money

id have 200 maybe at a stretch 250 for a front end, thats forks, clamps, wheel, calliper and brake lever.

 

[john_aero]

forks are a no go as the shop had 2 wrong legs,one was a 48mm leg of a 07 bike the other was 46mmof a pre 07

will servicemine and then watch for mx forksdown line

 

[john_aero]

did bit work 2day

forks off a ktm enduro bike wiht hub, axek clamps and brakes

they are 48mm wp forks

headlight bracket mocked up

 

[john_aero]

got fairing bracket nearly finished

 

[john_aero]

good news here

but i hade butcher my brackets as i had elongate and ovalize all the holes to get everything to aling up.

so will make up new ones in time ones have everything done

headlight can do with being moved over slightly

 

[john_aero]

ok got 30min to make up a 2nd T-bar to hold the road book and dash

BUTTTTTTTTTTTTTTTT what fuck the whoe lot is arse ways and all twisted. then realised th epillar drill was off, even thoguh set at zero it wasnt lever

had re do it all again, made total bolox of it and then on top that broke the 4mm tap in the hle for rond bar. its now acting as a peg hahaha and will tack weld it up next week just made sure its secure

 

[john_aero]

where do all the wires go.............

 

[john_aero]

Dash from frotn and side showing all wiring in and tidies up. relayed all mounted on new alu brackets to keep fitting as close to stock as possible


Front wheel with smp pro rin SS spokes and custom 320mm floating disc

Relay fitted so i now have spare fuse powered in fuse box running 12v socket gps and road book. fuse is 30 amp. but there is still a 2amp fuse on gps/roadbook line and will fit 25amp fuse on 12v socket lin

 

[Hairnet600]

inspiration

 

[john_aero]

have .56 weight fork springs there. have order seals and oil and then forks done

mate running new spacers for hub off on lathe and i hve make a steering stopper and ignition mount up then bike is done

 

[john_aero]

Have just fit temp and sppedo sensors. bleed brakes and then make sure calliper sitting centre and job done

got painting over weekend. just want give it final coat of clear coat tomorrow to seal it all in. so far has 5 coats paint and 4 coats clear coat

 

[Kamikaze]

Nice, John.
I like the poetic licence on the Dakar logo.

 

[john_aero]

Nice, John.
I like the poetic licence on the Dakar logo.

ya said had do something to make it my own

 

[john_aero]

think left decal not at right angle

have 4 brackets make up and still waiting on sensors arrive then bike done

dry layup now tonight