640 Adventure Tank Guards - Rally Raid Engineering

[michael1968]

Hi all,

I've been getting a bit of interest on my website (mostly from advriders) about the Carbon/Kevlar Tank Guards I've been developing for the KTM 640 Adventure, I thought it was about time I started a thread in the vendors section to keep you all updated.

First a little background; I've been messing around with composites for quite a few years, I'd made a few parts for my bike (heavily modified 97 F650 Funduro) and figured that maybe someone else might want them also. So I started a small (very small) business making composite parts for motorcycles called Rally Raid Engineering, for more info you can check out my website;

www.rallyraid.weebly.com

So onto the tank guards, last year another inmate asked me to make a set of kevlar tank guards for his 2002 640 Adventure. He wanted quite a bit more coverage than the others I've seen, the result is below;



From that tank I took a mould and have been filling, sanding and painting it into the plugs for the new guards which can be seen here;



These are the final shape of the finished part bar the cutouts for the radiator vents, so you can get an idea of the protection they'll provide. The finished part will be two layers of Carbon and two layers of Kevlar, you can choose what layer you would like on the outside, Kevlar is better for abrasion restance. Like all Rally Raid Engineering parts these will be made with an epoxy matrix and vacuum bagged.

The price will be AUD150 (about the same as USD right now) plus postage from Australia, contact me for a postage quote.

I'm not taking orders yet, I have had about 25 people contact me, I'll email them offering a set before I put them up for general sale.

The normal leadtime will be 4 to 6 days apon reciept of payment but keep in mind that I'm only one man and unfortunatly this isn't my full time job.

I'll post up here when I have the prototype ready, hopefully before the end of next week.

If you have any questions about the tank guards or any other of my parts please ask them here or contact me via my website.

Cheers,
Michael

------------------------------------------------------------------------------------------------------------------

Update:

The Guards are now ready, please PM or contact me via my website if you would like a set. I'll let you know an eta and then send you an invoice via PayPal when they are ready to ship.

Some example postage costs (in AUD, via airmail, with tracking) are;

US (mainland) & Canada $35.90
Most of Europe & UK $45.05

Australia;
Sydney $13.80
Melbourne $16.70
Adelaide $17.20
Perth $19.85

Attaching the Guards:
Depending on how permanently you want to attach them you can either use strong double sided tape or a polyurethane based adhesive like Sikaflex 227 or similar. You can run the tape or a bead of adhesive around the perimeter of the guards and a cross through the centre. I used Sika 227 on the Kevlar Guards above.

The finished Guards;

[Droptarotter]

Yep, I'm still interested as per my earlier email. There just might be 2 of us interested in western Canada.

A preference for me would be to NOT have the left side guard protect the petcock as I have removed that petcock and the extra lower protection will interfere with the access to the tool pod on the Rock Hard Rally Gear skid plate.


Anyone else in the area interested? Maybe we can cut down on shipping costs if we grab a bunch of them.

Cheers

[Ol'Muley]

I've got a '98 will these guards fit? Definitely interested

[michael1968]

Originally Posted by Droptarotter

Yep, I'm still interested as per my earlier email. There just might be 2 of us interested in western Canada.

A preference for me would be to NOT have the left side guard protect the petcock as I have removed that petcock and the extra lower protection will interfere with the access to the tool pod on the Rock Hard Rally Gear skid plate.


Anyone else in the area interested? Maybe we can cut down on shipping costs if we grab a bunch of them.

Cheers

Hey mate, I'm happy to combine shipping. I'm thinking of making petcock protection an option, the guards don't have any at this stage.

You've been added to the list.

Originally Posted by Ol'Muley

I've got a '98 will these guards fit? Definitely interested

I'm really not sure, I think there is some difference in the earlier tanks, the moulds for these were taken of a 2002 model.
Maybe someone with a bit more knowledge of 640 tanks can chime in.

Cheers,
Michael

[Droptarotter]

I think the main change was the locking gas cap on the 04-07 models.........or 05 in the US......I'm not 100% sure on this??

Cheers

[explodingmouse]

I think the other change was the move from a 28 litre tank in models up to and including 2003 to 25 litre from 2004 onwards.

[explodingmouse]

Hi Im interested whenever your ready.

[michael1968]

Hey all,

I just layer the final layer of fibreglass on the moulds, tomorrow I'll trim them. If all goes well I'll be laying up the prototype over the weekend.

Cheers,

Michael

[michael1968]

Originally Posted by explodingmouse

Hi Im interested whenever your ready.

No worries mate, I'll add you to the list.

[R80gs/pd]

You can put my down for one set. 2002 640 ADV. you have a PM
thanks

[swinterc]

Hey there,
Well I think I emailed you a while back about tank guards. Don't forget about me I'm still interested.

[Ol'Muley]

Any updates?

[michael1968]

Originally Posted by Ol'Muley

Any updates?

Yes, I've made the moulds but I wont be able to do any more work on them till after the 14th of April, I'm racing in the Condo 750 rally (advrider thread here) and have been flat out preping my bike for that.

Cheers,

Michael

[jrozar]

Hopefully these will come to market soon, I've been looking for a set for almost a year.

[Jaws285]

Oh oh! Please put me in for a set for my 2000 adventure.
I will PM