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Old 03-15-2012, 11:44 AM   #196
HappyGoLucky
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Happy Birthday mate, wishing you the very best!
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Old 03-15-2012, 12:20 PM   #197
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Quote:
Originally Posted by Locul@hotmail.com View Post
hmmm. I have maybe been explaining this wrong. Or my lack of written english isnt capable of explaining well.

Tachometer and dash is the same.
Ahh I'm with you now. Sorry about that. Your English is better than my Danish.

Happy Birthday
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Old 03-16-2012, 12:17 AM   #198
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Not wanting to be thought of as a smart ass.... I might add a few coments on glassing as we go. The only way to learn is to just do it. The more you do the better you get. If someone coments you can learn faster. Anyone can glass. You can make anything you can think of. It's one of the most satisfying experiences you can have. Every time you approach your bike you see the artistry that you created. The trick is to imagine what you want and then think of ways that you can make it, what can you use to get that shape to use as a mold. For example I had to make a battery box for a shoria so I used aluminum sheet. Shape it into a mold CF glass it.

This thread has a huge subscription so I think it's worth the time.

Two layers of carbon would be enough with a small strip in the bends/around the edge for the screen. It's easy to go overboard with carbon..... In the end you are wasteing money an adding to much weight. I do this all the time and in the end I do it again........ My wife leaves for the other side of the world in 12 hours. I have one month of uninterrupted workshop time........ I will live of pizzas and light beer..... Power Tools and beer do not go together.
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Old 03-16-2012, 01:00 PM   #199
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Thanks for the comments. Hugely appreciated. Yes im noob and the only way is ofcourse just dig in and get going. Ive had no regrets so far. Maybe the amount of carbon as you say, but its a learning curve as most of this project is. I will say there are 2 very important people making this project possible. Sren(garage owner, self learned mechanic and electrician), Svane(soldier friend and good mechanic). Both of them has helped me tremendously. ohh...and the account has suffered a bit. Untill now i have loved it and it keeps getting more and more fun. I just cant stay away from the project. I agree with the self made things. The good feeling when you look at it and im damn proud. Again thanks for the thoughts on the trial and error. And please anyone, chime in with your thoughts.
Now into what happened today. Another package for me.


The COOLER, at last i can dig into this.


The difference from LC8 to RC8.


Now i dont have to make the Y split before the inlet to the cylinders(with the LC8 radiator - only one outlet), which probably would put the flowratio down. So im confident that the extra money spend is the right way.


First encounter, as expected, is the mounting points.


Gotta cut something...Hopefully tomorrow.


Jumped further into some template for the intakes. Pretty straight foreward but i havent thought out the plan for this.


And some thoughts about the layout for the dash area. Gps on top, left - tire pressure, middle - dash, right - voltmeter. More will come. GIZMOS



Thanks for looking.

Ohh almost forgot some new documentary tools.


Timelapse of my day.
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Old 03-17-2012, 09:49 AM   #200
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Quote:
Originally Posted by K2m View Post
I will live of pizzas and light beer..... Power Tools and beer do not go together.
speaking of constructive suggestions, I suggest you skip the beer and go straight to the scotch, theeeeen wash the scotch down with the beer

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Old 03-21-2012, 03:34 PM   #201
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I forgot to mention the habit I got into in the late 70s. My mates and I would ride around the country going to bike rallies. There was one nearly every weekend. It was difficult to carry enough beer, with camping gear along some wet fire trial in the middle of winter....... So we carried some Stones green ginger wine to mix with the beer. You drink 2 inches of beer then pour the Stones in. It Intensifies the effect of beer





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Old 03-21-2012, 08:13 PM   #202
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waaay cool, that honda looks sweet and not afraid to get dirty
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Old 03-23-2012, 01:30 AM   #203
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Bonus Porn

Quote:
Originally Posted by Locul@hotmail.com View Post
6: Safari tanks –
This is a one of the bigger showstopper though its probably manageable. As Safari tanks make their tanks now it is not possible to weld in them (heat). Because the original tanks absolutely cant be welded I was pretty much stuck with this problem. I contacted Safari tanks and they said they could make a single pair of the old (swelling/deforming) batch. This will make it possible to bend the areas were the RC8R sticks out. Especially the area with the oil cooler is tough. Plus some other lesser critical areas.
Another problem occurred while mounting this engine. I lost the lower mounts for the tanks. I have not had the chance to look into this yet. The engine has some mounts in it but I will not be mounting “crash” protection to my engine. I am thinking of an L shaped piece of steel bar between the tanks. This will make the tanks “ok” sturdy for lesser impacts. If I then mount the touratech bashplate it will have plenty of frame sturdiness. Especially the critical front impact weakspot with the L shaped brace. This bike will of course not see the KTM 530 assignments. This will be for highspeed gravel stone chips and the tip-over sturdiness.

I have been thinking about this for a while. These Safari tanks would make a great template to mold from. There is no paint to damage. Plastic would work without even wax. You could apply some polish or wax/release compound to say the outside put two/three layers of carbon or I would use Darnell cloth/epoxy resin. Remove, then do the same on the inside

So you would have 2 sides of one tank. You could modify the inside by cutting out the parts that hit the motor....... then put foam and shape a new section.

When you finish you may have 4 parts for one tank. You glue these together and end up with the skeleton of a tank that fits. You use this to build your final tank from....... say 8 layers of carbon. Anything is possible..... new bottom mounts tank caps Fuel taps that do not leak.

So I'll do an update now on my bike and how I made my tanks. This will put into perspective what I have said above.

The biggest challenge for me was to design the foam to fit around the airfilters. I really wanted to carry as much fuel as possible without going to high with regard to center of gravity. Our KTMs carry a lot of fuel low but forward towards the front. For Dakar and so no the design is good as the rider can slide up onto the tank enduro stile. Also they are always in the dirt. For the touring rider our full tanks start at a fuel station. Then a ride on a tar road for some distance before hitting the dirt. It really dose not matter where fuel is carried for this part. When you get to the dirt the bulk of the fuel is in the wrong place with the weight over the front wheel. I wanted to carry the fuel higher and have it more centered when I hit the dirt.

There is also a move of the oil tank to under the seat, A Shorai battery, and a new thicker, smaller, Alloy radiator. These cost about $400 and are made by the same people that make radiators for V8 Supercars (Bathurst 1000 Mt Panorama) Some Adventure Monster Led lights (with dimmer for low beam...... hit high and both beams are at full intensity. Lite as )

So first you have to shape the foam. In the beginning I was going to make the faring and tank together, but this was very difficult.........







So once you have the shape you put a few layers of Darnel cloth/epoxy resin....... this becomes the skeleton from which to work to build the final shape..... Fuel cap, taps, level sensor etc.



Time to open it up.......



and clean it out (big job)













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K2m screwed with this post 03-23-2012 at 01:44 AM
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Old 03-23-2012, 03:17 AM   #204
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OK These are the head lights and some instruments. I really get all hot and sweaty when I look at that Racetech Oil pressure/temperature gauge. A nice lite digital volt gauge similar to yours Mikael.

I'm inspired by Mikael's dash. I have a similar need for this size. I like the way it angles in so I will do the same.





My project, about 4 months on, is at a stage where I can put things together and get an idea on what it will look like when finished. I use a piece of foam, exact dimensions, to test that the radiator will clear the wheel.









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Old 03-23-2012, 06:27 AM   #205
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Awesome thread, keep the posts coming.
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Old 03-23-2012, 02:50 PM   #206
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Wow K2M. The wife IS out of town. THAT is a big project. Holy cow. I will try to make the welding instead of the whole tank. I just cant get hold of safari office, that is a bit dissapointing. I keep trying and if anyone gets through please give me the connection. Still need the PE code or just to buy 1kg of the materials used for these "old" batch tanks. K2M, could/would you try? I will send you some danish quality beers if so

Ive just received the cooler with the new mountingpoints today. Pictures will come. My friend Svane came up with a genius idea where to mount the complete key/ignition setup. More carbon/kevlar/epoxy/resin incomming and a lot of small pieces. After getting some positive answers at the thread with CJs new airintake, i will measure tomorrow to see if this will fit. If so, im game.

Even parts for my 530 are in bound.

Updates will be sunday...
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Old 03-24-2012, 04:44 PM   #207
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No worries Mikael. I know Robin. He gave me the best piece of advice for building fiberglass tanks. He took the time to explain mechanical, and chemical bonding.

I was going to be one of the early testers for the safari 9x0 tanks. The good thing was that you got to keep the tanks. There was just one little problem. I was off to Istanbul on holiday. Being mid January I took my alpine touring skis with me and ended up in a place called Erzurum in Turkey. It would drop to -29 at night. What a wonderful place. I was able to Lang Lauf, from the ski resort, to within 200 meters of my hotel in the city centre.

I ended up being there for a couple of months and when I got back there had already been problems with tank swelling, and the situation had changed.......... So I missed out on my free tanks

Such is life I will do my best...... leave it with me

Istanbul is a must see city. The food is delightful. The Police were riding around two up on GS Airheads. The layers of history..... Topkapy!!!! http://en.wikipedia.org/wiki/History_of_Istanbul

But ............ there is no getting away from the Golden Arches







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Old 03-28-2012, 03:43 AM   #208
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Just saw a picture of the prototype 12xx KTM is building. Mikael yours is much better. No answers yet on plastic.

I closed the tank up today. Before doing it I filled it full of water one liter at a time.

So the big answer is:-

6 liters to cover the low fuel level sensor.

28 liters full tank

22 liters in the rear tanks

50 liters in total

In travel use that will mean 22 liters to reserve. at that point, the fuel in the rear tanks will take you back. So you have 6liters or about 84km to decide your fate

I like the way the light falls on the tank in these shots











Tomorrow I'll Carbon the tank. Big job as I want a chemical bond..... round 8/12 layers. I like my tanks crash proof regardless of cost/weight.

I'm very happy with the capacity....... 28Lt ......I do not think I could have planed it better. I can not be bothered with the Mathematics of working it out.
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Old 03-28-2012, 03:11 PM   #209
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Hi K2M

Love the build. Very complex. Keep posting.

And ive got an answer from Safaritanks today.

"
Hi Mikael,
I can send some welding material to you, we are happy to send this to you free of charge if you are able to pay for the postage AU$20.00 (air mail)
Please let me know if this is ok and if you would like to pay the postage charge by credit card .
Regard
Veronica
"

That is FOOKING great and super service. Wow. This could be the last big obstacle cleared. Small stuff will ofcourse emerge but im a happy camper right now.
Today has been a super day. The new batch of carbonstuff has arrived, the broken part for my fork, rear brakedisc(SD wheeels), 42 rearsprocket(the largest which fit the SD wheels)...and by friday ive got 14 days of vacation again. YES.
Pictures is on the way. All for now as im going back to the basement to carbon the shit out of old 950 parts...

Im not sure it will be better then the new 12xx K2M, but it will surely be very different and hopefully keep some offroadability. Btw i will estimate my fuel capacity around 55l, but this can variate as i dont know how smooth the welding will go.

more to come...
K2M 12xx
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Old 03-28-2012, 08:34 PM   #210
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Great news on all fronts..........

Your bike will be better because KTM are building a BMW (that's where the money is). You are building a dirt bike

I love the look of that radiator. Hi temp clear coat maybe ????? to keep it looking good............
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