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KTM640Dakar 04-01-2005 08:03 PM

KTM 640 Rallye skid plate (Group effort)
I wanted to pose a question to everyone about the Rallye skid plate toolbox that everyone wants but know one can afford. There seems to be enough talented people on this forum that we could as a group build these skid plates if we all helped. My idea is to build skid plates with the tool box or boxes to oem skid plates. I have the ability to weld aluminum all day long, but do not have a way to stamp out the indivdual parts. If someone in the forum could stamp out the aluminum I could weld them to either an OEM aluminum skid plate or an after market one. What does everyone think? There seems to be about 30 of us on this thumper forum at any one time.

ChrisC 04-01-2005 08:15 PM

You might want to take this up with Flanny before you go much further. He's very experienced at this endeavor...

Renazco 04-02-2005 04:07 AM

After much thought, I reconsidered adding more weight to the front end of the bike and decided to build a rear tool box. I would like to see a better skid plate though as the stock one seems really flimsy.

soloyosh 04-02-2005 04:43 AM

I can't offer any manufacturing help but if it'll fit my SXC, I'll pony up cash for it.


scuzzy 04-02-2005 05:13 AM


Originally Posted by soloyosh
I can't offer any manufacturing help but it'll fit my SXC, I'll pont up cash for it.


Likewise :thumb

overlandr 04-02-2005 05:50 AM

Seem to recall that there was a lot of talk around a year ago about a group project on a custom design one at group prices. The thread will be there somewhere - google?

BlitzBike 04-02-2005 08:38 AM

Flanny made blueprints but, could not get the fabricating price down to an acceptable level so he refunded all of our monies.

KTM640Dakar 04-02-2005 11:48 AM

Well Flanney, how much of the cost's were associated with welding?

Arch 04-02-2005 12:17 PM

Flanny's a 950 guy now, but as mentioned above, the rally bash/tank thing didn't prove affordably doable. Search through threads started by Flanny (scroll down) to see how it all unfolded.

Your best bet is try & find one overseas from the usual suspects, and they do turn up for sale from individuals every so often.

meat popsicle 04-02-2005 01:47 PM

I think these fellas are mistaken, KTiM had one fabricated for himself for the low low price of 250... a third of what they ask for new ones. This is a good possibliity, just need someone who can stamp aluminum parts.


who else am I forgetting who has mentioned fabrication...? :ear

One suggestion right off: the KTM rallye skidplate boxes bolt on and off, so you can remove them but still keep the skidplate. This would also make em easier to deal with as people wouldnt have to send you their skidplate.

The Thread:

KTM640Dakar 04-02-2005 02:38 PM

I would assume most everyone has a drill. We could fab up the boxes and leave it to each person to drill the tabs and flanges on their own. If we keep everything square it may be easier to bend the aluminum. Would two toolboxes be a good design? I'm not sure I would need a water tank.

BlitzBike 04-02-2005 03:03 PM

Yes, two tool boxes is the ticket.

KTM640Dakar 04-02-2005 03:19 PM

If anyone has drawings of the petcock side of the toolbox? I will start with that one.

BlitzBike 04-02-2005 06:59 PM

We need flannys input since he had it all drawn up and figured out at one point.
Maybe he will loan us his blue prints?

Mack 04-02-2005 07:21 PM

IIRC, BlownCJ has the drawings Flanny made up.

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