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jesusgatos 08-11-2012 12:28 PM


We're the Katz brothers, Robo-Boogie and Tyler and I. We've spent the last few years developing a small line of highend dirtbike parts, and now we're finally getting ready to launch our new company, GatosBros. I'm sort of a self-styled inventor/designer/builder, Robo-Boogie is studying manufacturing technology at Chico State University right now, and Tyler is a business guy. We're pulling together to launch a family business and this is most definitely a garage start-up. Designing and manufacturing and testing and patenting these products has been... expensive. But we're putting everything we've got into this and we hope it shows. The first round of parts are all out getting anodized and laser-etched right now, and we're just finishing-up the website. But we're excited to share, so here's a sneak-peek, a look at what kind of stuff we're making (and hopefully, selling):

We've made a conscious decision not to even bother trying to hit any specific price-points. When I'm doing contracted design-work, clients often impose limitations and make profit-driven decisions that make good business sense, but frustrate me as a designer. One of the things that makes this so much fun is that we have the freedom to design and manufacture the very best parts we can; and our motivation is entirely selfish. These are the parts that WE want to use. Everything is designed and made right here in the USA, we're using the best materials, there's a lot of intricate machining, expensive anodizing, etc. The bottom line is that we could make these parts much cheaper, but that's not the point. We want every product we make to be the best-in-category, and if it's not, we don't want to put our name on it.

Everything we sell comes with a We're Not Assholes 99% of the time (most of the time) guarantee*. Not a lifetime warranty, or a 100% customer satisfaction guarantee. Let's be reasonable. But if you have a legitimate problem with any of our products, we want to know about it, and we'll do our best to work it out.

*Except for Jesse. He's kind of an asshole, but he's not in charge of customer service/satisfaction.

jesusgatos 08-11-2012 12:28 PM

universal steering stabilizer mount
Here's a quick introduction to the universal steering stabilizer mount that I originally designed for Easton. Most steering stabilizer mounts are bike-specific; meaning that companies have to design, manufacture, and inventory a multitude of different stabilizer mounts. In contrast, the solution I came up with fits almost every conceivable application, from 5-20mm offset (in 1mm increments) and 94-106mm width (infinitely adjustable within that range). The only bikes we're aware of that it won't fit are some of the older Huskys (perches are too narrow to even fit a stabilizer between them) and KTM's, which use an entirely different setup (see below).

The secret is in the double-stacked eccentric cams, which are oriented in a way that allows for the width and offset to be adjusted independently. The way it works is that each eccentric cam is in a slot, so the cams are only constrained in one direction. The slots are perpendicular to each other, so when you pass a bolt through the cam-holes, the whole assembly becomes fully-constrained. Little bit hard to explain, but we'll post more details, pics, and videos soon. But we've been developing and testing different iterations of this stabilizer mount for several years now, and this is the end result.

The minimum height added under the handlebars is only 24mm (less than 1"), and height can be further adjusted using 2 & 5mm spacers above and below the steering stabilizer mount, in different combinations. All components are made out of 7075 aluminum.

So now there's a steering stabilizer mount that you can move from bike-to-bike along with your stabilizer. The only thing you might have to buy is a new stabilizer tower.

Patents Pending

jesusgatos 08-11-2012 12:29 PM

KTM-specific steering stabilizer mounts
Simply put, we designed this KTM-specific stabilizer mount in order to solve the problems we've had with other companies' stabilizer mounts. But we're not trying to slam any other companies or products, only explain how we've made our stabilizer mount better.

1) Seemed like almost every time we crashed, they would 'smoosh' and deform right under the handlebar mounting perches. We tried them all, and they all seem to have the same fatal flaw - there's just not enough of an adequate mounting surface under the handlebar perches. Material is removed from the area right under the handlebar perch mounting surface in order to clear the two bolt-heads that secure the stabilizer to the tripleclamp - and that's precisely where they were all deforming. Time after time, and it was getting expensive.

2) They also, for some reason, only use two 10mm bolts to secure the stabilizer mount to the upper tripleclamp. Probably not the best idea, especially when the hardware that KTM uses is barely adequate at stock-height (every other manufacturer uses 12mm handlebar perch mounting hardware). Then you add all that additional leverage when you raise the bars to clear the stabilizer, and no wonder they don't hold-up. After some of the more severe crashes, the stabilizer mounts actually pulled away from the tripleclamp and twisted.

3) The last point to make about these stabilizer mounts and their shortcomings is that they don't preserve the adjustability that KTM designed into the handlebar mounts.

We experimented with modifying some of these steering stabilizer mounts. Never really intending to make anything to sell, just hoping to come up with something that would work for us. I put one in the mill, shaved-off some of the extra height, and drilled out the threaded holes so that I could use two additional 10mm bolts to secure the stabilizer mount to the upper tripleclamp.

Robo bought a new stabilizer mount right before Vegas-to-Reno last year. He also drilled-out the threaded holes and then machined a little bit of material off the top of the mount, along with the allen-bolts, hoping that would offer the perches a little more support. In all fairness, it was a pretty spectacular crash that knocked Robo-Boogie out of that race, but it still failed.

We were frustrated and determined to come up with something that would be absolutely bulletproof. But we didn't want to make a steering stabilizer mount with integrated handlebar perches because we appreciate the adjustability that the KTM mounting system affords.

So here's what we came up with:

Our stabilizer mount is comprised of the main steering stabilizer mount and a series of modular spacers (15mm) and top-caps (5/10/15mm) that can be used in different combinations to achieve the desired amount of rise. The total stack-height of our new stabilizer mount without any spacers and using the shortest top-caps, only adds 23mm to the height of the handlebar perches (lower than anything else out there). Aggressive trailriders and racers will appreciate this. On the other end of the spectrum, more casual dualsport riders and rally racers who are looking for more rise will find it, in 5mm increments and up to 53mm (2") of additional height.

All components are made out of 7000-series aluminum and use four bolts to secure the perches and stabilizer mount to the upper tripleclamp. The only other offering that rivals ours is made by Highway Dirtbikes and it looks like a great product. Similar strength, and only a little bit less adjustable. Our stabilizer mount was designed to work with our handlebar perches, but will also work with any/all of the stock KTM perches, and in any position. Which means that you can put your bars exactly where you want them.

Patents Pending

jesusgatos 08-11-2012 12:29 PM

handlebar perches
When it came time to design a set of handlebar perches to complement our steering stabilizer mounts, I applied everything that I learned working with Chuck Teixeira at Easton on accessories for their EXP product line.

Typical 1 1/8" handlebar perches are about 25mm wide, and ours are 45mm wide, which results in more than a 40% increase in clamping surface area.

Additionally, we're using a clevis on one side of the perch and two 6mm bolts on the other side, which actually yields a lot more effective clamping force than two 8mm bolts, and that clamping force is distributed more evenly over a larger area.

The material that has been removed from the webbing between the pinch-bolts allows each pinch-bolt to apply and maintain clamping force without affecting the other.

There is also a generous radius along the inside edge of the handle perches, which helps to reduce stress-risers that cause handlebars to fail.

These perches are also offset front-to-back (3mm) and side-to-side, so they can be configured to work with just about every conceivable application.

We're making these in KTM-specific (30mm tall, 10mm hardware & 20mm slots) and universal (35mm tall, 12mm hardware & flat-bottom) versions.

jesusgatos 08-11-2012 12:30 PM

c-clamp outer handguard mounts
Seems like every time we had to replace our grips, we'd end up having to buy new handguard mounting bolts too. They were always bent, and as a result, did not secure the handguards very well. Our new 'c-clamp' outer handguard mounts take the hardware out of shear and make the whole handguard assembly a lot stronger. We've also verified that they'll work with all currently available metal wrap-around handguards.

Patents Pending

jesusgatos 08-11-2012 12:31 PM

pinchy outer handguard mounts
Our 'pinchy' outer handguard mounts go even one step further. In addition to taking the outer handguard mounting hardware out of shear, there's a pinch-bolt that clamps around the outside of the handlebars. Why? Well, the expending wedges and threaded inserts that all of the currently available handguards use are simply not very effective when it comes to resisting rotational forces - and as a result, we've all come to accept having to twist our handguards back into place after they take a hard hit. So we put a lot of thought into coming up with a better solution. We extensive crash-testing that we've done (thanks Robo) leads us to believe this might be it. Just like the c-clamp outer handguard mounts, these are also universal and will work with any of the currently available metal full wrap-around handguards.

Patents Pending

If you're wondering what the big deal is, just think about the threadless headset revolution that swept through the bicycle industry back in the 90's. We're not reinventing the wheel, but all these incremental improvements make for better motorcycles and better riding.

jesusgatos 08-11-2012 12:31 PM

handlebar-mounted inner handguard mounts
The idea of clamping handguard mounts to the tapered part of 1 1/8" handlebars always seemed kinda silly to me, as even the smallest hits knock them loose. so our inner handguard mounts clamp onto the meaty 1 1/8" flat section of the handlebars, right outside the handlebar perches. This is not a new idea; just an obvious one, well-executed.

We started off by creating a 3D CAD model that included the critical measurements of all the popular handlebars and then physically measured the fit of every pair of metal full wrap-around handguards we could find. Then we used all that data to find the ideal location for each of the three holes in our inner handguard mounts. All of this work was extremely time-consuming, but the result is an exceptional fit, with almost any combination of handlebars and handguards.

jesusgatos 08-11-2012 12:32 PM

side-mount tripleclamp-mounted inner handguard mounts
We were tired of bending/breaking Cycra's shitty side-mount tripleclamp handguard mounts, so we made these. Much stronger, sleeker, and they have integrated tie-down points! We like these tripleclamp-mounted inner handguard mounts so much that if they fit KTM's, we'd run them on all our bikes. They're practically indestructible. And they use the same inner handguard mounting points as the handlebar-mounted version, so you can expect the same exceptional fit.

jesusgatos 08-11-2012 01:39 PM

arched footpegs
I started this project out of curiosity more than anything else. I know there are a few other companies making arched footpegs, but these are unique. The basic idea is that there are five effective rows of teeth on a large radius and the rider’s feet will always be in contact with at least three of those rows, maintaining a more consistent amount of traction as they lean forward and backwards over the bike. These footpegs are still in development, so this is just a preview of what we're working on and things to come...

jesusgatos 08-11-2012 04:32 PM

Think that's all for now. Lots of technical information to add about all of this different products, and I'll be editing and adding to these posts over the next few days.

ktm950se 08-11-2012 07:18 PM

Damn, mighty impressive for an introduction!


Petrolburner 08-11-2012 08:42 PM

Wow :tb Best of luck!

tmotten 08-11-2012 09:14 PM

Outstanding work. :clap:clap:clap

DaveRMS 08-11-2012 09:21 PM

Nice stuff, Jesse.

skidrow 08-12-2012 01:31 PM

great job
i love all the and effort put into your products. good luck with the r and d

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