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-   -   Digital Desert camouflage the KLR650 step-by-step walk thru (http://www.advrider.com/forums/showthread.php?t=632548)

klm4755 10-27-2010 09:22 PM

Digital Desert camouflage the KLR650 step-by-step walk thru
 
Enclosed is a step by step walk thru outlining a project to digital desert camouflage a KLR650. I have seen several camo style bikes. The USMC adopted the KLR650 as it's primary motorcycle. The USMC version is shown below:
http://i52.photobucket.com/albums/g2...%201/usmc1.jpg
The USMC KLR

I start all projects with a review of the components to be removed and modified
http://i52.photobucket.com/albums/g2...PA220071-1.jpg
There are multiple techniques to apply camouflage.
1. Paint
2. Vinyl graphic decal
I attempted to paint the bike one part/section at a time. I started with a mirror and front brake hub. To paint digital desert graphic the process is as follows:
1. Remove and mask component
2. Degrease and clean with alcohol
http://i52.photobucket.com/albums/g2...P9040017-1.jpg
3. skuff part with 220 grit sandpaper metallic, 400 grit for plastic part
http://i52.photobucket.com/albums/g2...P9040014-1.jpg
4. Primer 2x coats for metallic part, no primer for plastic part
http://i52.photobucket.com/albums/g2...P8290002-1.jpg
5. Paint with light color first Krylon fusion khaki 2-3 coats
http://i52.photobucket.com/albums/g2...P8290006-1.jpg
6. get female type digital template decal sticker (from e-bay)
http://i52.photobucket.com/albums/g2...P9050052-1.jpg
http://i52.photobucket.com/albums/g2...1/P9050053.jpg
mask the item roto hub shown
http://i52.photobucket.com/albums/g2...P9120107-1.jpg
http://i52.photobucket.com/albums/g2...P9050054-1.jpg
adding stickers to mirror
paint with next darker color, mirror shown
http://i52.photobucket.com/albums/g2...P9120108-1.jpg
krylon darker flat camouflage color
http://i52.photobucket.com/albums/g2...P9120106-1.jpg
decals after usage, they are reusable....At this point I realized this is not going to work...The process is too time consuming and the results are marginal....So on to plan B
http://i52.photobucket.com/albums/g2...PA220086-1.jpg
I ordered couple digital desert sheets from www.powersportswraps.com, they are shown below next to real digital desert camo
http://i52.photobucket.com/albums/g2...PA220087-1.jpg
3M material
http://i52.photobucket.com/albums/g2...PA220088-1.jpg
peal back and apply like a sticker, still not really happy with the pattern. So, on to a plan C
http://i52.photobucket.com/albums/g2...PA220084-1.jpg
I ordered some double sided carpet tape from Lowes, Mildew resistant, very sticky....about the same as high quality duct tape
http://i52.photobucket.com/albums/g2...PA080040-1.jpg
added a small swatch to the hood of my CRV....Held up well over 8 months thru 6 washes, lots of various weather
http://i52.photobucket.com/albums/g2...P8290003-1.jpg
I ordered 10 yards of 100% nylon digital desert camouflage for $20 from e-bay. I ended up using about 70% of the material. I also ended up using about 6 rolls of carpet take, About 70% of the visable bike is covered in the camo cloth, 25% is painted in either Khaki (Krylon fusion ultra flat camouflage) or sand color for the high temp parts. About 5% is not pained, wheels, valve stems and such
http://i52.photobucket.com/albums/g2...P9050031-1.jpg
Apply the double sided tape to the camo cloth, Use a heat gun to wick the adhesive into the nylon fibers, I also used a roller (shown later) to press the tape up against the fabric.
http://i52.photobucket.com/albums/g2...P9060081-1.jpg
peal back tape protection layer with Exacto knife
http://i52.photobucket.com/albums/g2...P9140120-1.jpg
I ended up consuming about 100 blades Exacto blade # 11 works best
http://i52.photobucket.com/albums/g2...P9050033-1.jpg
peal back layer
http://i52.photobucket.com/albums/g2...P9050034-1.jpg
lay part on top and keep creases to minimum, unfortunatly one the tape touches the part, it is very difficult to re-position
http://i52.photobucket.com/albums/g2...P9050035-1.jpg
work thru, in this case, a part of the front fender
http://i52.photobucket.com/albums/g2...P9050036-1.jpg
like so, full coverage
http://i52.photobucket.com/albums/g2...P9050038-1.jpg
use Exacto to trim excess
http://i52.photobucket.com/albums/g2...P9050039-1.jpg
trim out all holes
http://i52.photobucket.com/albums/g2...P9050041-1.jpg
use heat gun to drape cloth and tape to form tight to contour
http://i52.photobucket.com/albums/g2...P9050040-1.jpg
finished part
http://i52.photobucket.com/albums/g2...P9060068-1.jpg
use soldering iron to cauterize the trim lines
http://i52.photobucket.com/albums/g2...P9060070-1.jpg
after soldering iron to edge, keeps from fraying the ends
http://i52.photobucket.com/albums/g2...P9060073-1.jpg
fork brace parts completed
http://i52.photobucket.com/albums/g2...P9140127-1.jpg
headlight guard covered
http://i52.photobucket.com/albums/g2...P9140130-1.jpg
headlight guard after trim
http://i52.photobucket.com/albums/g2...P9140118-1.jpg
turn signal
http://i52.photobucket.com/albums/g2...P9140119-1.jpg
let tape connect, not lap over
http://i52.photobucket.com/albums/g2...P9140123-1.jpg
trim back with scissors
http://i52.photobucket.com/albums/g2...P9140122-1.jpg
trim edge
http://i52.photobucket.com/albums/g2...P9140124-1.jpg
finished turn signal, part paint part camo
http://i52.photobucket.com/albums/g2...P9140131-1.jpg
turn signal attached to headlight guard
http://i52.photobucket.com/albums/g2...P9110091-1.jpg
dissemble dash
http://i52.photobucket.com/albums/g2...P9110093-1.jpg
mask dask
http://i52.photobucket.com/albums/g2...P9110095-1.jpg
sand
http://i52.photobucket.com/albums/g2...P9110097-1.jpg
ready for paint
http://i52.photobucket.com/albums/g2...P9120099-1.jpg
couple of coats
http://i52.photobucket.com/albums/g2...P9050049-1.jpg
fork brace
http://i52.photobucket.com/albums/g2...P8290004-1.jpg
skid plate
http://i52.photobucket.com/albums/g2...P9040020-1.jpg
for fork guard, the tape does not stick, so I'll use a 3M adhesive spray for rubber
http://i52.photobucket.com/albums/g2...P9050024-1.jpg
stretch out the rubber fork guard and apply the cloth with adhesive, allow to dry, the cloth adheres very well
http://i52.photobucket.com/albums/g2...P9050025-1.jpg
http://i52.photobucket.com/albums/g2...P9050026-1.jpg
http://i52.photobucket.com/albums/g2...P9050028-1.jpg
paint other parts
http://i52.photobucket.com/albums/g2...P9100090-1.jpg
prep front faring
http://i52.photobucket.com/albums/g2...P9140134-1.jpg
front faring
http://i52.photobucket.com/albums/g2...P9210154-1.jpg
back side of faring
http://i52.photobucket.com/albums/g2...P9060075-1.jpg
front forks
http://i52.photobucket.com/albums/g2...P9060077-1.jpg
wrap around fabric
http://i52.photobucket.com/albums/g2...P9060078-1.jpg
contact ends together
http://i52.photobucket.com/albums/g2...P9060079-1.jpg
trim ends
http://i52.photobucket.com/albums/g2...P9060080-1.jpg
small seam exposed
http://i52.photobucket.com/albums/g2...P9060083-1.jpg
front end

http://i52.photobucket.com/albums/g2...P9120112-1.jpg
running lights and fender
http://i52.photobucket.com/albums/g2...PA220083-1.jpg
dash area
http://i52.photobucket.com/albums/g2...P9240157-1.jpg
finished front area
http://i52.photobucket.com/albums/g2...P9050029-1.jpg
checking swatches on bike.....
To be continued..........
Keithm

Yooper_Bob 10-28-2010 07:37 AM

WOW!! :eek1

bete 10-28-2010 07:59 AM

As allways your projects are outstading, but you do reilize you will lose your bike and never find it now. :rofl bete.

SCQTT 10-28-2010 08:20 AM

The other option would be just to spend all that time riding it. :D

Tarka 10-28-2010 09:10 AM

That`s a hell of a lot of work,but it looks awesome.



All that trouble to make others think their digital cameras are faulty. :D

norcal-SAHD 10-28-2010 09:32 AM

I love that you left the reflectors on the fork legs. :lol3

klm4755 10-28-2010 02:26 PM

Quote:

Originally Posted by norcal-SAHD
I love that you left the reflectors on the fork legs. :lol3

I believe the reflectors are req'd by law.
Keithm

klm4755 10-28-2010 05:54 PM

The fuel tank removed from the bike
http://i52.photobucket.com/albums/g2...2/P9300005.jpg
drain the fuel
http://i52.photobucket.com/albums/g2...2/P9300007.jpg
remove the fuel cap, mark the major direction of up/down as the camo patter should be aligned vertically and horizontally.
http://i52.photobucket.com/albums/g2...2/P9300011.jpg
gross cut the size needed. I'll use 3x sections to envelop the tank
http://i52.photobucket.com/albums/g2...2/P9300012.jpg
start on side
http://i52.photobucket.com/albums/g2...2/P9300013.jpg
trim edges as you go
http://i52.photobucket.com/albums/g2...2/P9300014.jpg
side view 1st layer
http://i52.photobucket.com/albums/g2...2/P9300015.jpg
added protector back on sticky layer, don't want to press down yet, will form a seam at the tank crease
http://i52.photobucket.com/albums/g2...2/P9300017.jpg
add additional top layer, match the exposed layers together
http://i52.photobucket.com/albums/g2...2/P9300020.jpg
allow to contact
http://i52.photobucket.com/albums/g2...2/P9300021.jpg
press together
http://i52.photobucket.com/albums/g2...2/P9300022.jpg
trim flash
http://i52.photobucket.com/albums/g2...2/P9260012.jpg
paint exhaust guard and tank guards
http://i52.photobucket.com/albums/g2...2/P9250003.jpg
clean, scuff (with 220 grit sand paper), prime engine and exhaust with high temp primer
http://i52.photobucket.com/albums/g2...2/P9260004.jpg
paint engine with high temp stove paint, sand color
http://i52.photobucket.com/albums/g2...P9260007-1.jpg
paint carb, and exhaust
http://i52.photobucket.com/albums/g2...2/P9270038.jpg
close-up of paint on engine exhaust
http://i52.photobucket.com/albums/g2...2/P9260025.jpg
standoff view of progress
http://i52.photobucket.com/albums/g2...2/P9030010.jpg
camo the tank guard bags, I used a 3M adhesive
http://i52.photobucket.com/albums/g2...2/PA030018.jpg
finished left bag
http://i52.photobucket.com/albums/g2...2/P9300004.jpg
need to mount the bag here
http://i52.photobucket.com/albums/g2...2/PA020001.jpg
size the mounting panel needed
http://i52.photobucket.com/albums/g2...2/PA020002.jpg
trim as needed
http://i52.photobucket.com/albums/g2...2/PA020004.jpg
de-burr edges
http://i52.photobucket.com/albums/g2...2/PA020005.jpg
good fit
http://i52.photobucket.com/albums/g2...2/PA020006.jpg
quick check fit...A-ok
http://i52.photobucket.com/albums/g2...2/PA020008.jpg
interior bag bracket, tap 4 mm hole to support mounting bracket
http://i52.photobucket.com/albums/g2...2/PA020009.jpg
fits like so..
Camo the mounting panel
http://i52.photobucket.com/albums/g2...2/PA030016.jpg
both sides
http://i52.photobucket.com/albums/g2...2/PA030017.jpg
trim flash
http://i52.photobucket.com/albums/g2...2/PA030019.jpg
attach mounting plate on bike, with heavy duty cable ties
http://i52.photobucket.com/albums/g2...2/PA020012.jpg
bolt bags to bike mounting panel
http://i52.photobucket.com/albums/g2...2/P9260030.jpg
Tank faring
http://i52.photobucket.com/albums/g2...2/P9260033.jpg
engine paint job
http://i52.photobucket.com/albums/g2...2/P9260008.jpg
paint steel horn...notice the high pressure line. I separated the actual horn from the air source
http://i52.photobucket.com/albums/g2...2/P9270046.jpg
the air horn mounted here
http://i52.photobucket.com/albums/g2...2/P9270047.jpg
front view
http://i52.photobucket.com/albums/g2...2/P9170144.jpg
high temp paint used sand color
http://i52.photobucket.com/albums/g2...2/P9260034.jpg
fuse box shown
http://i52.photobucket.com/albums/g2...2/P9260035.jpg
front view
http://i52.photobucket.com/albums/g2...2/P9300018.jpg
top of tank installed
http://i52.photobucket.com/albums/g2...2/P9260022.jpg
front view with lights on
http://i52.photobucket.com/albums/g2...2/PA030023.jpg
progress so far
http://i52.photobucket.com/albums/g2...2/P9300023.jpg
side view
To be continued.......
Keithm

klm4755 10-28-2010 06:31 PM

http://i52.photobucket.com/albums/g2...3/PA030025.jpg
side panel
http://i52.photobucket.com/albums/g2...3/PA030027.jpg
trim edges
http://i52.photobucket.com/albums/g2...3/PA030028.jpg
edge sample
http://i52.photobucket.com/albums/g2...3/PA030026.jpg
side panel on bike and overall progress
http://i52.photobucket.com/albums/g2...3/PA060034.jpg
Rear parts off for paint prep
http://i52.photobucket.com/albums/g2...3/PA070037.jpg
sanded rear foot pegs
http://i52.photobucket.com/albums/g2...3/PA080038.jpg
painted parts
http://i52.photobucket.com/albums/g2...3/PA080039.jpg
painted exhaust
http://i52.photobucket.com/albums/g2...3/PA170029.jpg
rear wheel cleaned, sanded, masked, ready for primer
http://i52.photobucket.com/albums/g2...3/PA170031.jpg
rear wheel after paint
http://i52.photobucket.com/albums/g2...3/PA200038.jpg
remove masking on rear wheel
http://i52.photobucket.com/albums/g2...3/PA200040.jpg
painted wheel
http://i52.photobucket.com/albums/g2...3/PA190033.jpg
rear brake line covered
http://i52.photobucket.com/albums/g2...3/PA190035.jpg
finished rear brake system
http://i52.photobucket.com/albums/g2...3/PA160021.jpg
primer swing arm
http://i52.photobucket.com/albums/g2...3/PA160016.jpg
misc parts painted
http://i52.photobucket.com/albums/g2...3/PA120001.jpg
rear rack, I seemed to get better at keeping the fabric applied without creases as I went
http://i52.photobucket.com/albums/g2...3/PA120002.jpg
underside view
http://i52.photobucket.com/albums/g2...3/PA120003.jpg
looks good
http://i52.photobucket.com/albums/g2...3/PA140005.jpg
set-up for panniers
http://i52.photobucket.com/albums/g2...3/PA140006.jpg
just flip on material, best to use a single piece
http://i52.photobucket.com/albums/g2...3/PA140007.jpg
flip again
http://i52.photobucket.com/albums/g2...3/PA140010.jpg
camo pannier lock
http://i52.photobucket.com/albums/g2...3/PA140009.jpg
pannier lock before and after
http://i52.photobucket.com/albums/g2...3/PA220057.jpg
pannier cables...lower line = 12v line to power phone, ipod and heated clothes, upper line to control heated gloves and jacket
http://i52.photobucket.com/albums/g2...3/PA220056.jpg
inside pannier
http://i52.photobucket.com/albums/g2...3/PA220058.jpg
swing arm view
http://i52.photobucket.com/albums/g2...3/PA220062.jpg
back view pannier lock, turn signals, plate frame, extended fender, and rack shown
http://i52.photobucket.com/albums/g2...3/PA220063.jpg
right side view
http://i52.photobucket.com/albums/g2...3/PA220064.jpg
underside view
http://i52.photobucket.com/albums/g2...3/PA220046.jpg
seat...draped with 3x sections
http://i52.photobucket.com/albums/g2...3/PA220048.jpg
Right side pannier
http://i52.photobucket.com/albums/g2...3/PA220049.jpg
front view
http://i52.photobucket.com/albums/g2...3/PA220050.jpg
left side view
http://i52.photobucket.com/albums/g2...3/PA220051.jpg
left side pannier, knobs control heated gloves and jacket
http://i52.photobucket.com/albums/g2...3/PA220045.jpg
front offset view
http://i52.photobucket.com/albums/g2...3/PA220066.jpg
dash view
http://i52.photobucket.com/albums/g2...3/PA220054.jpg
left side view
http://i52.photobucket.com/albums/g2...PA220070-2.jpg
ready to ride...notice I have a 2" drop kit
http://i52.photobucket.com/albums/g2...PA220067-2.jpg
Enjoy
Keithm

space 10-28-2010 06:42 PM

Holy.
Crap.

:thumb

doogiepooch 10-28-2010 07:11 PM

#1 - I like it, took bawlz and imagination to do that to your bike.
#2 - I'm curious to see what it looks like after a few months in rain, mud, road debris, chain grease etc. But the patch on your car still looked good so maybe it will look like new also.
#3 - How do you like your windsheild addition? I've been thinking about ordering that thing.

schattat 10-28-2010 07:35 PM

Damn, you're quite the artist!!! :thumb
If I ever need a paintjob done I'll let you know!!! :freaky

scrminbanshee 10-28-2010 08:17 PM

I think you might have to much free time on your hands.

pluric 10-28-2010 09:49 PM

Sorry, after all that work it's kinda WTF?

Each their own.

Ben99r1 10-28-2010 10:31 PM

That's crazy in a good way. You better go to a surplus store and buy a matching outfit. Ben


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