Sport Bike to an Enduro or Dual Sport

[dunesnstars]

Originally Posted by dhillr

How many stitches did it take?

Lots!
Keep in mind the picture had to be maginified 1000X to be able to see the extent of the damages!

[dunesnstars]

Originally Posted by sanjoh

You are a fabricating fool.

What did you mount the front of your gravel guard to? Looks like the exhaust?

Yes the front is mounted to the exhaust. I welded a small stainless steel tab to the header. This is another reason I'm a huge proponent of bolting, since aluminum and steel cannot be welded together.

So then I was able to bolt the front of the guard to that tab. The rear of the pan is bolted to brackets I made which is then bolted to the original bolt holes where the oil pan brackets used to be. The brackets I made are actually bent in case I smack something hard enough, the brackets should bend and still protect the exhaust. At least in theory, that's how it should work. Hope this answers your question.

[dunesnstars]

Originally Posted by RAGBrian

Been kicking around again about getting a Versys and making it a dual sport. Sheesh, should also have considered the Ninja as well. You build is giving me ideas! Watching with wonderment and taking notes.

You can get Ninjas pretty cheap and you will end up with your very own unique bike. I'm too short for any of the dual sports out there, so I didn't really have a choice but the build has been a lot of fun. But you gotta enjoy this kinda stuff for it to work out well.

Go for it!

[Laughingdawg]

Originally Posted by dunesnstars

This is another reason I'm a huge proponent of bolting, since aluminum and steel cannot be welded together.

That can't be true, because every Aegis cruiser is an aluminum superstructure welded to a steel hull. It may be ridiculously expensive in comparison to the value of the bike. But it's definitely possible.

[mpowers]

Originally Posted by Laughingdawg

That can't be true, because every Aegis cruiser is an aluminum superstructure welded to a steel hull. It may be ridiculously expensive in comparison to the value of the bike. But it's definitely possible.

fwiw
I did a quick search on the cruiser, but my guess would be they used explosion welding to fuse a alum and steel pieces (thus making clad steel), then welded the alum deck structure to the alum side of the fused plate. This is considered cold fusion, where welding stick, mig, tig, shor arc, etc is hot fusion.

Other than that, there are a few solders out in the market that more or less glue the two together-not truley fused and have no real mechanical strenght. These are inexpensive, but would have failed with the first hit from a rock.

[dunesnstars]

Originally Posted by mpowers

fwiw
I did a quick search on the cruiser, but my guess would be they used explosion welding to fuse a alum and steel pieces (thus making clad steel), then welded the alum deck structure to the alum side of the fused plate. This is considered cold fusion, where welding stick, mig, tig, shor arc, etc is hot fusion.

Other than that, there are a few solders out in the market that more or less glue the two together-not truley fused and have no real mechanical strenght. These are inexpensive, but would have failed with the first hit from a rock.

Yeah, what he said!

[gvthnks]

Originally Posted by mpowers

fwiw
I did a quick search on the cruiser, but my guess would be they used explosion welding to fuse a alum and steel pieces

yup, that's it.

[dunesnstars]

Wow! New tires are mounted, racks and side cases are installed! Looking really good!!!

[dawgwhat]

Originally Posted by dunesnstars

Wow! New tires are mounted, racks and side cases are installed! Looking really good!!!

need pic's or it didn't happen

[dunesnstars]

Originally Posted by dawgwhat

need pic's or it didn't happen

Why you don't trust me? I can't believe how good it looks. It's really looking like it should have always been a dual sport!

[dawgwhat]

Originally Posted by dunesnstars

Why you don't trust me? I can't believe how good it looks. It's really looking like it should have always been a dual sport!

I do trust ya...

but you have 2 put up some pic's or it didn't happen

[dunesnstars]

On Thursday, the fittings came in for the coolant tank as well as another set of turn signals and the Givi sidecases.

Yesterday, the Givi racks (thank you Grainbelt!) and tires came in. Within a few hours, the new Avon distanzias were mounted and balanced. This morning, the wheels were installed. And they look pretty damn good!

Still not finished but here's a quick preview of ENja now...










Tomorrow is paint day! Everything gets taken apart, sanded, primered and painted. While waiting for the paint to dry, I need to mess around with the wiring a little and ENja should be almost ready to ride!

Can't wait!

[Funkydevil]

Lookin' pretty darn effin' sweet. I would ask about paint, but I'll just wait and see. Good Job!!!

[dawgwhat]

Lookin good gf

almost there

[dhillr]

Looks real nice

Now let's hit some gravel & break that puppy in!!!