ADVrider

Go Back   ADVrider > Bikes > Thumpers
User Name
Password
Register Inmates Photos Site Rules Search Today's Posts Mark Forums Read

Reply
 
Thread Tools Search this Thread Display Modes
Old 11-05-2009, 12:10 PM   #1
Exile OP
The Mundane and The Magic
 
Exile's Avatar
 
Joined: Mar 2009
Location: Illinois
Oddometer: 197
Exile's DR650 TAT Build & Prep

Well I finally got my DR650. I have started my bike mods already and I figured I would share and see what input I could gain as well. These are the beginning preparations for the TAT. My friend and I will be making the trek summer of '10.

The Bike: 2004 DR650, 5k Miles.

The Mods (so far): 7.62mm Ammo cans (2), Pelican Top Box, homemade racks, driving lights, power adapter.

The pictures:

I didn't get a shot of the bike before I did everything, but I'm pretty sure everyone knows what a stock DR looks like.

Finished top rack. Everything fastens to the existing mounting places, just needed to get longer bolts.


Top rack with Pelican case mounted.

I ended up drilling my holes off center so I found some small round rubber tube patches and stuck those over my giant holes and pierced the bolts through. Instant weatherproofing!

I have pictures of the design process for the side racks but they are grainy (camera phone), so here is the finished product. Powder coated side and top racks.

Mounted on the bike. The rear turn signals are fasten to the top rack since I did away with the stock grab handles.

The finished product of my labor including the ammo cans.


Driving lights from Wal-Mart...$14.95. Mounted to the reflector brackets. I have since drilled new holes above to remount the reflectors.

Fabricated a weatherproof switchbox to mount the independent switch to the battery and the power adapter. I have since redone the mounting so it looks nicer...(i.e. hidden zip ties)



Fabrication of the windscreen is next.
Things still to get: TrailTech X2 headlight(ordered), Acerbis Front Fender(ordered), Corbin Seat, IMS Tank, Skid Plate, Tires, Handguards, and much more!

I do have an issue that I have run into that I could use some input with. I have my ammo cans bolting to the side rack as of now. However I am trying to design a 'quick release' system to be able to remove them easily at my discretion. If anyone has some ideas they would be helpful. I have seen the 'hockey puck' idea but I don't know how it works well enough to implement my own.

Any and all input is welcome. Criticize away!
__________________
06 Ducati 999 | 66 Ducati 250 | 03 Suzuki DR650

My Site
TAT 2010 RR!
DR650 Stator Rewire

Exile screwed with this post 04-16-2010 at 09:03 AM
Exile is offline   Reply With Quote
Old 11-05-2009, 12:47 PM   #2
Off Limits
Really?
 
Off Limits's Avatar
 
Joined: Jun 2009
Location: Camp Snoopy
Oddometer: 3,318
i have an 09 dr. im going to get the suspension done also. also im going to do the ims tank, corbin seat. i bought the baja windscreen from cee bailey. it work very well and i just bolted it right up to the stock number plate. i will be using soft bags that go over the seat, cant remember the name. killer loop? when i went on my 700 miler i found myself using the passenger pegs a lot to get more comfortable on the long straights.
__________________
We are not Assholes, we just see things the way they are! Selfish people live longer.
Off Limits is offline   Reply With Quote
Old 11-05-2009, 03:28 PM   #3
Exile OP
The Mundane and The Magic
 
Exile's Avatar
 
Joined: Mar 2009
Location: Illinois
Oddometer: 197
What you can do instead of using you passenger pegs, is bolt a "highway" bar on to the skid plate (assuming you will get one) so that you can extend your legs out. And Nelson Rigg makes a good pair of over the seat side bags.
__________________
06 Ducati 999 | 66 Ducati 250 | 03 Suzuki DR650

My Site
TAT 2010 RR!
DR650 Stator Rewire
Exile is offline   Reply With Quote
Old 11-22-2009, 08:02 PM   #4
Exile OP
The Mundane and The Magic
 
Exile's Avatar
 
Joined: Mar 2009
Location: Illinois
Oddometer: 197
Since classes are out for fall break I got started putting all my new parts on.


I finished the stator rewire. Then put on the following parts; Acerbis Front Fender, Trail Tech X2 headlight, Emgo hangguards, Corbin Seat, Skid Plate, and a Twin Air Air Filter. IMS tank is being shipped.



By the end of the week I should have my side racks rebuilt to bring my ammo cans higher and make them easily removable as well as painting the ammo cans since they are starting to rust. I will also be making my own windscreen and highway pegs.
__________________
06 Ducati 999 | 66 Ducati 250 | 03 Suzuki DR650

My Site
TAT 2010 RR!
DR650 Stator Rewire
Exile is offline   Reply With Quote
Old 11-28-2009, 09:53 AM   #5
Exile OP
The Mundane and The Magic
 
Exile's Avatar
 
Joined: Mar 2009
Location: Illinois
Oddometer: 197
Well I was finally able to test out my bike on the trails and see if I had any regrets on the decisions I had made.

My friend and I took our DR's out on the trails at the beginning of the week. We went on ATV trails in our area through the woods, creeks, and muddle hills and was it ever challenging with these big bikes. It was a scenario of man handle or be man handled...

I enjoyed every moment! The bikes performed great and even survived some hard crashes and many tip-overs. One thing that seemed to help handling was lowering the front forks. Mine are lowered to the handle bars while my friends were up at stock. After switching bikes, it seemed that my DR was the more stable of the two. I also had 80lbs more weight on my bike than he did since I am 40lbs heavier and I had my ammo cans on, another 40lbs. This may have helped stable my bike a bit but I'll leave that to speculation.

We didn't get pictures of the trail riding but got some dirty ones after.




The next day my IMS tank came and I installed it and rebuilt my racks while my friend built his.

Here are some photos from the day.


The goal of rebuilding my racks was to make them symmetric, since I'm a bit of a perfectionist, and to raise up the boxes.




Here are my friends racks for his Nelson-Rigg soft bags.




At this time I also cut off the metal lip on one end of each box and welded that side shut so the lids can hinge up stand on end. Then I painted the boxes so they won't rust anymore.




As of yesterday, after the paint had cured, I started making the new attachment brackets for the ammo cans.




The bracket will mount on the bottom of the rack and then I only need to secure two screws at the top and my boxes are mounted.



And the finished product. Now I just have to make a windscreen.






__________________
06 Ducati 999 | 66 Ducati 250 | 03 Suzuki DR650

My Site
TAT 2010 RR!
DR650 Stator Rewire
Exile is offline   Reply With Quote
Old 11-28-2009, 10:17 AM   #6
Gear_Grinder
Life Long Rider
 
Gear_Grinder's Avatar
 
Joined: Nov 2009
Location: Good old PA
Oddometer: 34
That is freaking awsome. Im looking forward to see how you build the windshield. I built mine but could have put more time into to make it a lot better. Not that I'm not satified with it but I almost always see room for improvment after building something. As for the ammo can saddle bags that is my next goal. I really like how you did your up. Im just waiting for time to make mine. Living in and apartment really makes it a challenge when you have to go to a friends house to build everything. Do you know if that stator rewire is able to be done to all years or just the newer ones, I have a 92 and would really like to do it if possible? Keep up the great work. Im looking forward to seeing more.
__________________
In need of two wheels.
Gear_Grinder is offline   Reply With Quote
Old 11-28-2009, 10:23 AM   #7
Exile OP
The Mundane and The Magic
 
Exile's Avatar
 
Joined: Mar 2009
Location: Illinois
Oddometer: 197
The stator rewire should be able to be done to all years. The post on Thumper Talk has gotten more input so I'll post it there to make sure. Check it out here.
__________________
06 Ducati 999 | 66 Ducati 250 | 03 Suzuki DR650

My Site
TAT 2010 RR!
DR650 Stator Rewire
Exile is offline   Reply With Quote
Old 11-28-2009, 10:33 AM   #8
Pigford
British
 
Pigford's Avatar
 
Joined: Sep 2009
Location: North Dorset, UK
Oddometer: 903
Does look smart - but be honest, don't the top front edges of the boxes dig into your legs Looks like they might limit movement on the bike ?
Pigford is offline   Reply With Quote
Old 11-28-2009, 11:01 AM   #9
Exile OP
The Mundane and The Magic
 
Exile's Avatar
 
Joined: Mar 2009
Location: Illinois
Oddometer: 197
Not at all surprisingly. I can even ride my fiance comfortably.
__________________
06 Ducati 999 | 66 Ducati 250 | 03 Suzuki DR650

My Site
TAT 2010 RR!
DR650 Stator Rewire
Exile is offline   Reply With Quote
Old 12-01-2009, 04:59 PM   #10
smilin jack
Grandpa Adventurer
 
smilin jack's Avatar
 
Joined: May 2008
Location: Lebanon Oregon
Oddometer: 1,225
Home made Farkles-Like a lot !!!

Exile, WOW, I really like your style. Making your own farkles! Cool.

I've made a few for my 2006 DR650... like a package shelf on the left side, attached to the left rear foot peg mounting bolts. It will hold a case of beer or a plastic fuel jug. Probably more things too.

Made a bracket for the right side of the bike that bolts to the right rear turn signal mount bolt and the right passenger foot peg mounting bolts. I bolt on my Kolpin rifle case or the home made chainsaw bar sheath that holds the 20" bar and Stihl 031 saw (1978 model-got new). Works well for opening logs on trails.

Think your rack and pannier frames are cool, and will be doing some copying, if you don't mind.

Dave
smilin jack is offline   Reply With Quote
Old 12-01-2009, 09:34 PM   #11
Exile OP
The Mundane and The Magic
 
Exile's Avatar
 
Joined: Mar 2009
Location: Illinois
Oddometer: 197
Thanks, I'm glad you like it.

You'll have to post some pictures of your shelf/brackets, though is a 20" blade really necessary?

Copy away, that's why I posted. The racks are made out of 1/4" square tubing, 1/4" (I think) hot rolled steel, and some 1/8" flat stock.
__________________
06 Ducati 999 | 66 Ducati 250 | 03 Suzuki DR650

My Site
TAT 2010 RR!
DR650 Stator Rewire
Exile is offline   Reply With Quote
Old 12-02-2009, 03:25 PM   #12
alonzo
Misadventurer
 
alonzo's Avatar
 
Joined: May 2007
Location: Northwest Ozarks
Oddometer: 404
Quote:
Originally Posted by Exile
Copy away, that's why I posted. The racks are made out of 1/4" square tubing, 1/4" (I think) hot rolled steel, and some 1/8" flat stock.
1/4"??? Really... Looks more like 1/2" from here (well,,, that's pretty far away though...) -- alonzo
__________________
2006 Suzuki DR650SE

1978 BMW R80/7
2009 BMW F650GS (do you think a new BMW every 30 years is too much?)

2006 Yamaha XT225
1970 Triumph Bonneville T120R

"The difference between genius and stupidity is that genius has limits."
Ąsǝʞıq ʇɹıp ɟo ɟɟo ʎɐʇs pןnoɥs noʎ ǝqʎɐɯ uǝɥʇ sıɥʇ pɐǝɹ uɐɔ noʎ ɟı
alonzo is offline   Reply With Quote
Old 12-02-2009, 09:25 PM   #13
Exile OP
The Mundane and The Magic
 
Exile's Avatar
 
Joined: Mar 2009
Location: Illinois
Oddometer: 197
The 1/4" is measured from the inside, if I'm not mistaken.
__________________
06 Ducati 999 | 66 Ducati 250 | 03 Suzuki DR650

My Site
TAT 2010 RR!
DR650 Stator Rewire
Exile is offline   Reply With Quote
Old 12-03-2009, 05:05 AM   #14
jgrady1982
Studly Adventurer
 
jgrady1982's Avatar
 
Joined: Dec 2008
Location: Cleveland, Ohio
Oddometer: 775
Man freaking great job on your project. I have 2 20mm ammo cans at home waiting to do the same thing...once Santa brings me my MIG welder for Christmas. Everything looks great!

-Jack
jgrady1982 is offline   Reply With Quote
Old 12-03-2009, 05:55 AM   #15
boxermoose
Now fully goosed
 
boxermoose's Avatar
 
Joined: Sep 2003
Location: Gulf Coast TX
Oddometer: 2,828
You can make some pretty good pannier mounts by using hockey pucks

The advantage is no metal to metal and some give in a off
__________________
Sometimes you get the ABAT....and sometimes the ABAT gets you
boxermoose is offline   Reply With Quote
Reply

Share

Thread Tools Search this Thread
Search this Thread:

.
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On

Forum Jump


Times are GMT -7.   It's 06:20 AM.


Powered by vBulletin® Version 3.8.5
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
Copyright ADVrider 2011-2014