X challenge rebuild

[GFJ]

Apparently Touratech did one at some point, but I've just been on their site and couldn't find it. Not seen one 2nd hand for ages either.

Could try 'Vern' of this parish for a bespoke item. Based in Cheshire and knows his way around a welder.

 

[JohnnyBoxer]

TT will sell you a steel one
Living where you do - I would take a long weekend break to the Black Forest in Jan & buy one direct - about 450 miles from Calais each way

 

[dean0n0]

Erik had some http://www.hotrodwelding.nl/news.php?news_id=27 not cheap though.

 

[Losttheplot]

Right, subframe is a no go can't find anyone to fabricate me one every one I've took it to has said no problem then haven't been able to for one reason or another so I've got to bite the bullet and go to Bmw has any of you guys had a steel subframe of them if so how much ?? in advance .

Carl, What sort of weight are you putting on the back of your bike? the standard subframe is pretty good if braced- i haven't managed to break mine yet.

 

[Robbo1961]

I spoke to Erik he did have one 600 euros he reckoned it might be cheaper from Bm over here !!

 

[Robbo1961]

Do you know what nathan I think you might be right did you beef yours up at all or change the inserts ? Weight wise I'm traveling light sleeping bag bed roll a few spares tools as light as poss really .

 

[Robbo1961]

By the way JB the tank bag arrived cheers mate

 

[Losttheplot]

Do you know what nathan I think you might be right did you beef yours up at all or change the inserts ? Weight wise I'm traveling light sleeping bag bed roll a few spares tools as light as poss really .

I just had a local welder fit a plate in between the rails at the back. I took around 16kg's of luggage and spares with me across the US (turns out i didn't need half of it), and didn't have any problems.

I'll see if i can dig some pictures out of the extra bracing

 

[Losttheplot]

This thread shows the work i had done on the subframe:

http://www.ukgser.com/forums/showthread.php/358847-Breaking-point-on-XChallenge-rear-frame?highlight=subframe

 

[JohnnyBoxer]

By the way JB the tank bag arrived cheers mate

Thanks for letting me know

 

[mikedefieslife]

The few reported sub frame breakages tend to be on the top and in line or there abouts with the first hole, as that's where the bottom part of the frame ends, and where the greatest stress is when carrying a load that bouncing up and down on the back.

If I was strengthening mine, I'd look at adding a small 4mm or so bar a few inches long over the top subframe, thus doubling the wall thickness of the subframe tubing in that area.

The alternative would be to weld a triangle type structure underneath the subframe.

The TT subframe is £423. The technical data for it has not been released so you can only guess as to how much it might be able to carry, but should be in line with the 09 OEM one. You probably don't want to do, but if you ever did want to carry a pillion, you'd need to drill your own holes for the pegs.

BMW have stock of the 09 subframe and you can get one delivered to the UK for around £550. The 09 bikes can carry an additional 30kg according to the data sheet.

 

[Robbo1961]

Touretech don't supply them any more I rang them last week so it's either the Bm one or strengthen it, what do you think abt cutting the frame on the weak parts and fitting steel inserts either side and as you say a triangle type structure ?

 

[Timpo]

Pannier rails will put some triangulation in to the rear structure of the bike, and with Wolfman soft cases, you have a decent set up for both road and trail based trips.
Avoid having your heaviest items high up, and mounted on the rear rack part of the bike. Tent and sleeping bag are best there, and up out of water's way should you do any fording....

 

[mikedefieslife]

I've got an email from them just a few months ago about it. They had to check with Germany but said they were available. Perhaps they've sold out.

I would rather a BMW one then TT anyway. I heard that some of the TT ones are out of alignment due to a manufacturing error.

Much cheaper to just get the original welded. Not hear of anyone try the steel insert route before. I don't know how hollow the frame is, i.e. if any welds or tapped areas would get in the way of a good fit. I think it would move the stress point to the lower opening of the subframe where the steel is inserted and could lead to that fracturing. Though as you say you'd have a triangle shaped support.

Personally I would just stick with doubling the thickness of the aluminium. Generally aluminium (though it depends what type) is half as strong as steel for just one third of the weight.

Something like highlighted in the image would below would suffice.

Note: the image isn't mine.

It's around that first bolt where all the stresses are, so strengthening there is the best fix. The second bolt/hole is pretty much redundant as far the stresses go.

 

[Robbo1961]

Thanks guys I think that's what I'm going to do now strengthen it, il let you know the outcome .

 

[r1d3rg652gs]

Nice bike. Which crashbars are the ones you have?

 

[r1d3rg652gs]

After some research it looks like hepco & becker.

 

[Robbo1961]

Sorry only just noticed your post, I'm not sure what bars they are as they was fitted when purchased the bike.

 

[Robbo1961]

This thread shows the work i had done on the subframe:

http://www.ukgser.com/forums/showthread.php/358847-Breaking-point-on-XChallenge-rear-frame?highlight=subframe

Thanks nathan that's really helpfull that's the route I'm going now!! .

 

[huskydog]

im just debating the adding of more fuel to my x challenge. think I may go for making my own tank that will run down the right hand side of sub frame. as far as sub frames go I would think that welding some more ali plates to standard frame would be best, and spend the money buying lighter kit to take with you, as having lighter kit will make your trip more pleasant. the lighter the bikes overall weight the better.