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Exile 11-05-2009 12:10 PM

Exile's DR650 TAT Build & Prep
Well I finally got my DR650. I have started my bike mods already and I figured I would share and see what input I could gain as well. These are the beginning preparations for the TAT. My friend and I will be making the trek summer of '10.

The Bike: 2004 DR650, 5k Miles.

The Mods (so far): 7.62mm Ammo cans (2), Pelican Top Box, homemade racks, driving lights, power adapter.

The pictures:

I didn't get a shot of the bike before I did everything, but I'm pretty sure everyone knows what a stock DR looks like.
Finished top rack. Everything fastens to the existing mounting places, just needed to get longer bolts.
Top rack with Pelican case mounted.
I ended up drilling my holes off center :doh so I found some small round rubber tube patches and stuck those over my giant holes and pierced the bolts through. Instant weatherproofing!
I have pictures of the design process for the side racks but they are grainy (camera phone), so here is the finished product. Powder coated side and top racks.
Mounted on the bike. The rear turn signals are fasten to the top rack since I did away with the stock grab handles.
The finished product of my labor including the ammo cans.
Driving lights from Wal-Mart...$14.95. Mounted to the reflector brackets. I have since drilled new holes above to remount the reflectors.
Fabricated a weatherproof switchbox to mount the independent switch to the battery and the power adapter. I have since redone the mounting so it looks nicer...(i.e. hidden zip ties) :D

Fabrication of the windscreen is next.
Things still to get: TrailTech X2 headlight(ordered), Acerbis Front Fender(ordered), Corbin Seat, IMS Tank, Skid Plate, Tires, Handguards, and much more!

I do have an issue that I have run into that I could use some input with. I have my ammo cans bolting to the side rack as of now. However I am trying to design a 'quick release' system to be able to remove them easily at my discretion. If anyone has some ideas they would be helpful. I have seen the 'hockey puck' idea but I don't know how it works well enough to implement my own.

Any and all input is welcome. Criticize away!

Off Limits 11-05-2009 12:47 PM

i have an 09 dr. im going to get the suspension done also. also im going to do the ims tank, corbin seat. i bought the baja windscreen from cee bailey. it work very well and i just bolted it right up to the stock number plate. i will be using soft bags that go over the seat, cant remember the name. killer loop? when i went on my 700 miler i found myself using the passenger pegs a lot to get more comfortable on the long straights.

Exile 11-05-2009 03:28 PM

What you can do instead of using you passenger pegs, is bolt a "highway" bar on to the skid plate (assuming you will get one) so that you can extend your legs out. And Nelson Rigg makes a good pair of over the seat side bags.

Exile 11-22-2009 08:02 PM

Since classes are out for fall break I got started putting all my new parts on.

I finished the stator rewire. Then put on the following parts; Acerbis Front Fender, Trail Tech X2 headlight, Emgo hangguards, Corbin Seat, Skid Plate, and a Twin Air Air Filter. IMS tank is being shipped.

By the end of the week I should have my side racks rebuilt to bring my ammo cans higher and make them easily removable as well as painting the ammo cans since they are starting to rust. I will also be making my own windscreen and highway pegs.

Exile 11-28-2009 09:53 AM

Well I was finally able to test out my bike on the trails and see if I had any regrets on the decisions I had made.

My friend and I took our DR's out on the trails at the beginning of the week. We went on ATV trails in our area through the woods, creeks, and muddle hills and was it ever challenging with these big bikes. It was a scenario of man handle or be man handled...

I enjoyed every moment! The bikes performed great and even survived some hard crashes and many tip-overs. One thing that seemed to help handling was lowering the front forks. Mine are lowered to the handle bars while my friends were up at stock. After switching bikes, it seemed that my DR was the more stable of the two. I also had 80lbs more weight on my bike than he did since I am 40lbs heavier and I had my ammo cans on, another 40lbs. This may have helped stable my bike a bit but I'll leave that to speculation.

We didn't get pictures of the trail riding but got some dirty ones after.

The next day my IMS tank came and I installed it and rebuilt my racks while my friend built his.

Here are some photos from the day.

The goal of rebuilding my racks was to make them symmetric, since I'm a bit of a perfectionist, and to raise up the boxes.

Here are my friends racks for his Nelson-Rigg soft bags.

At this time I also cut off the metal lip on one end of each box and welded that side shut so the lids can hinge up stand on end. Then I painted the boxes so they won't rust anymore.

As of yesterday, after the paint had cured, I started making the new attachment brackets for the ammo cans.

The bracket will mount on the bottom of the rack and then I only need to secure two screws at the top and my boxes are mounted.

And the finished product. Now I just have to make a windscreen.

Gear_Grinder 11-28-2009 10:17 AM

That is freaking awsome. Im looking forward to see how you build the windshield. I built mine but could have put more time into to make it a lot better. Not that I'm not satified with it but I almost always see room for improvment after building something. As for the ammo can saddle bags that is my next goal. I really like how you did your up. Im just waiting for time to make mine. Living in and apartment really makes it a challenge when you have to go to a friends house to build everything. Do you know if that stator rewire is able to be done to all years or just the newer ones, I have a 92 and would really like to do it if possible? Keep up the great work. Im looking forward to seeing more.:thumb :clap

Exile 11-28-2009 10:23 AM

The stator rewire should be able to be done to all years. The post on Thumper Talk has gotten more input so I'll post it there to make sure. Check it out here.

Pigford 11-28-2009 10:33 AM

Does look smart - but be honest, don't the top front edges of the boxes dig into your legs :huh Looks like they might limit movement on the bike ?

Exile 11-28-2009 11:01 AM

Not at all surprisingly. I can even ride my fiance comfortably. :wink:

smilin jack 12-01-2009 04:59 PM

Home made Farkles-Like a lot !!!
Exile, WOW, I really like your style. Making your own farkles! Cool.

I've made a few for my 2006 DR650... like a package shelf on the left side, attached to the left rear foot peg mounting bolts. It will hold a case of beer or a plastic fuel jug. Probably more things too.

Made a bracket for the right side of the bike that bolts to the right rear turn signal mount bolt and the right passenger foot peg mounting bolts. I bolt on my Kolpin rifle case or the home made chainsaw bar sheath that holds the 20" bar and Stihl 031 saw (1978 model-got new). Works well for opening logs on trails.

Think your rack and pannier frames are cool, and will be doing some copying, if you don't mind.


Exile 12-01-2009 09:34 PM

Thanks, I'm glad you like it. :D

You'll have to post some pictures of your shelf/brackets, though is a 20" blade really necessary? :eek1

Copy away, that's why I posted. The racks are made out of 1/4" square tubing, 1/4" (I think) hot rolled steel, and some 1/8" flat stock.

alonzo 12-02-2009 03:25 PM


Originally Posted by Exile
Copy away, that's why I posted. The racks are made out of 1/4" square tubing, 1/4" (I think) hot rolled steel, and some 1/8" flat stock.

1/4"??? Really... Looks more like 1/2" from here (well,,, that's pretty far away though...) -- alonzo

Exile 12-02-2009 09:25 PM

The 1/4" is measured from the inside, if I'm not mistaken.

jgrady1982 12-03-2009 05:05 AM

Man freaking great job on your project. I have 2 20mm ammo cans at home waiting to do the same thing...once Santa brings me my MIG welder for Christmas. Everything looks great!


boxermoose 12-03-2009 05:55 AM

You can make some pretty good pannier mounts by using hockey pucks

The advantage is no metal to metal and some give in a off

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