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Old 10-27-2010, 09:22 PM   #1
klm4755 OP
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Joined: Jun 2006
Oddometer: 575
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:


I start all projects with a review of the components to be removed and modified

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

3. skuff part with 220 grit sandpaper metallic, 400 grit for plastic part

4. Primer 2x coats for metallic part, no primer for plastic part

5. Paint with light color first Krylon fusion khaki 2-3 coats

6. get female type digital template decal sticker (from e-bay)

mask the item roto hub shown

adding stickers to mirror
paint with next darker color, mirror shown

krylon darker flat camouflage color

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

I ordered couple digital desert sheets from, they are shown below next to real digital desert camo

3M material

peal back and apply like a sticker, still not really happy with the pattern. So, on to a plan C

I ordered some double sided carpet tape from Lowes, Mildew resistant, very sticky....about the same as high quality duct tape

added a small swatch to the hood of my CRV....Held up well over 8 months thru 6 washes, lots of various weather

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

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.

peal back tape protection layer with Exacto knife

I ended up consuming about 100 blades Exacto blade # 11 works best

peal back layer

lay part on top and keep creases to minimum, unfortunatly one the tape touches the part, it is very difficult to re-position

work thru, in this case, a part of the front fender

like so, full coverage

use Exacto to trim excess

trim out all holes

use heat gun to drape cloth and tape to form tight to contour

finished part

use soldering iron to cauterize the trim lines

after soldering iron to edge, keeps from fraying the ends

fork brace parts completed

headlight guard covered

headlight guard after trim

turn signal

let tape connect, not lap over

trim back with scissors

trim edge

finished turn signal, part paint part camo

turn signal attached to headlight guard

dissemble dash

mask dask


ready for paint

couple of coats

fork brace

skid plate

for fork guard, the tape does not stick, so I'll use a 3M adhesive spray for rubber

stretch out the rubber fork guard and apply the cloth with adhesive, allow to dry, the cloth adheres very well

paint other parts

prep front faring

front faring

back side of faring

front forks

wrap around fabric

contact ends together

trim ends

small seam exposed

front end

running lights and fender

dash area

finished front area

checking swatches on bike.....
To be continued..........
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Old 10-28-2010, 07:37 AM   #2
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Old 10-28-2010, 07:59 AM   #3
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As allways your projects are outstading, but you do reilize you will lose your bike and never find it now. bete.
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Old 10-28-2010, 08:20 AM   #4
Zwei Kolben
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The other option would be just to spend all that time riding it.
This is SPARTA!
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Old 10-28-2010, 09:10 AM   #5
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Location: Across the pond.
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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.

I'd only waste my money if I didn`t spend it on all my bikes......
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Old 10-28-2010, 09:32 AM   #6
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Location: northern california
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I love that you left the reflectors on the fork legs.
01 KLR650
00 GasGas XC250
04 ttr125l
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Old 10-29-2010, 12:33 PM   #7
get in or go in
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Location: GB-Wisconsin
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ummmm yeah....that bike looks wrapped too tight.
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Old 10-30-2010, 04:23 PM   #8
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Location: minneapolis
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Have you ridden it in the rain yet? Those pegs might get a bit slippery

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Old 10-30-2010, 06:16 PM   #9
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Location: Ontario
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great work, but just because you can wrap the part doesn't mean you should.
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Old 08-25-2011, 07:16 PM   #10
Joined: Jul 2011
Location: Manitou Springs, CO
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Dear god why?

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Old 07-27-2012, 06:30 PM   #11
smilin jack
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Joined: May 2008
Location: Lebanon Oregon
Oddometer: 1,228
Camo KLR

Originally Posted by co-steve View Post
Dear god why?

Very nice job! Pretty much a work of art!

It's not what my DR needs, but I can see the idea for stealth camping, hunting and zombie attacks. I use a desert tan bike cover for camping concealment and it can double for a tent if a day trip turns into overnight.

The built in axe and shovel are great and will incorporate onto my bike. Thanks for thinking outside the "box".

Like the HI-VIZ vest and I wear them too (have several).


smilin jack screwed with this post 07-27-2012 at 06:39 PM
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Old 08-17-2012, 07:43 AM   #12
Neville1 to TT boys
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Joined: May 2004
Location: Rehoboth MA
Oddometer: 356
Originally Posted by co-steve View Post
Dear god why?

Because he wanted too, but I'm not a fan. Too complicated looking compared to a standard military bike. It's the difference between a gay dude wearing an earring back in the 70's to distinguish themselves, and that's like a modern mo in some pride parade in a banana hammock with multicolored hair wearing sandles and glitter.
1990 DR650S page
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Old 05-03-2012, 07:22 PM   #13
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Location: Portage ,PA
Oddometer: 2,464
Funny that people ragged on this guy ... And I bet everyone rode a bike that looked exactly like every other bike of that model . Good for him for doing what he wanted and liked , no shame in that . I worked with a guy that bought some tacky flame stickers from Walmart and placed them on his we Harley , thought it was the cats ass . Who cares , he liked it and rode the piss out of it
Pain heals. Chicks dig scars. Glory... lasts forever.
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Old 07-27-2012, 07:46 PM   #14
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so cool
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Old 09-11-2012, 04:35 PM   #15
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Joined: Jun 2012
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Cool2 ???????????????????????????????????????

Im seeing it with mine own eyes,but Im not believing it,WHY????Just WHY????
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