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Old 11-24-2013, 07:41 PM   #2266
jdrocks OP
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Quote:
Originally Posted by Highliner View Post
Been trying to get through this thread this weekend...
good luck with that, i can't find stuff in there myself. the updates for this build should help if you're following along. glad you're enjoying the read.

transforming the Versys into a gravel runner is surprisingly easy and inexpensive, big improvement in performance obviously. similar efforts are underway for the DL650 using the DRZ400 forks, the same as this build. i still think a build based on the 650 Ptwin is the better choice. depending on the direction of the build, the choice between the ER6 and Versys frame/subframe might not matter much. i've kept the subframe, seat, and related trim stock, and i prefer the Versys in that area.

regarding Montana in 2009, i think that kid driving the truck was asleep...and i was lucky.

the bike sat under the grain body for 3 hours in a 6L puddle of gas that drained from an auxiliary tank that was damaged when the bike was dragged through the turn upside down. the ignition was on the whole 3 hours, and i couldn't turn it off because the headlight support was bent down over the top of the key. no fire, no lack of adventure that day.

local rancher put a tractor tire patch on a hole in the rear tire i could stick an index finger through, damn, now i could run 80 again, and did.

i still think it's funny that during a 2700 mile ride home on an obviously wrecked bike, nobody who saw the bike asked what happened.
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Old 11-24-2013, 07:53 PM   #2267
jdrocks OP
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Originally Posted by MTrider16 View Post
All us Montanan's have the same story. BTW, what month day were you hit JD? I was thinking it was early July?

This link might make you a little homesick Highliner. Finding Content(ment)

June 11, 2009 was adventure day.
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Old 11-24-2013, 08:29 PM   #2268
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Originally Posted by jdrocks View Post
June 11, 2009 was adventure day.
Yeah, late for seeding too early for harvest. Like you said, the kid wasn't paying attention. David
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Old 11-25-2013, 06:50 AM   #2269
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Originally Posted by MTrider16 View Post
Yeah, late for seeding too early for harvest. Like you said, the kid wasn't paying attention. David
the guy was definitely moving wheat, maybe from bin to elevator. the dummy was so out of it that he almost ran over the bike a second time when i was trying to retrieve it from under the grain body.

we've all passed slow moving ag equipment on the highway, but i've changed my procedures since June '09.
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Old 11-25-2013, 05:50 PM   #2270
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Quote:
Originally Posted by MTrider16 View Post
All us Montanan's have the same story. BTW, what month day were you hit JD? I was thinking it was early July?

This link might make you a little homesick Highliner. Finding Content(ment)
Thanks, I"m glad you mapped it. It's a great perspective of how big the east side is. A ride like that out here would of put you in 5 states.

I'm fortunate to grow up on the prairie. Took me a while to learn to appreciate West Dakota. After graduating HS I migrated to the mountains around Bozeman, Helena, Flathead and Lincoln counties, I grew to appreciate That Missouri river country more and more. Though I do have to admit, it's been a long time since I've had to endure continuous weeks of -10F and ridiculous windchill.

If there would of been a picture of a big elk in your photos, I would of choked up and started going on about why in the hell I live so far away from home. This is the time of the year i really miss chasing big furry tasty critters and the elk steaks, burger and summer sausage that come shortly after. Next year I'm planning on coming home to get skunked by the elusive wapiti again.
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Old 11-25-2013, 06:01 PM   #2271
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Originally Posted by jdrocks View Post
good luck with that, i can't find stuff in there myself. the updates for this build should help if you're following along. glad you're enjoying the read.

i've kept the subframe, seat, and related trim stock, and i prefer the Versys in that area.

.
Between the previous build, the current build, the other forum, and the various other Dirt Ninja builds out there, I'm a bit overwhelmed by the sheer volume of information and entertainment from the ride reports and bike builds.

You mind sharing why you perfer the Versys frame over the Ninja?

I still have to read the other half of this thread and the one on the Versys site. Sorry if it's been covered.
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Old 11-25-2013, 06:59 PM   #2272
MTrider16
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If there would of been a picture of a big elk in your photos, I would of choked up and started going on about why in the hell I live so far away from home.
Funny you should mention wapiti, two of them surprised me as I was on the bench north of the UL bend. It was too dark for pics and they were still in velvet. It was the first time I saw wild elk in West Dakota even though I grew up here.

As far as living here, its kinda nice, we actually have jobs out here again.

Anyway, I'm clogging up the thread, its no wonder its hard to find build information.

David
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Old 11-25-2013, 07:06 PM   #2273
jdrocks OP
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Originally Posted by Highliner View Post
Between the previous build, the current build, the other forum, and the various other Dirt Ninja builds out there, I'm a bit overwhelmed by the sheer volume of information and entertainment from the ride reports and bike builds.
plenty of entertainment in there, for sure. for specifics on this particular build, you should stay with the build thread on ADV. the other forum thread has ride reports mixed in with a little bike building, or vice versa, i forget. if ya make it through this thread, your questions will be answered, most anyway.

i almost got one of those Wyoming elk this past June.
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Old 11-25-2013, 07:21 PM   #2274
jdrocks OP
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even though the DRZ forks have those beafy 49mm stanchions, i still use a fork brace which also doubles as the low fender mount. the centers of the Versys clamps are wider than the DRZ, gotta cut the fork brace in half to make it work for my purposes. this brace comes drilled, but not tapped, for 6mm fasteners. i drilled and tapped the same pattern for M8 bolts.



i had a late model ER6 fender, but it needs some trimming to work, so i started with a preliminary setup to see how everything would come together. once i decide on the fender height and positioning, i can adjust the fork brace and fabricate the fork brace saddle and fender mount. the fender mount fabrication get a little tricky because of the compound curves of the fender surface.

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Old 11-26-2013, 08:38 PM   #2275
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the fork brace needs to be joined together, then the fender mount. the fork brace has about 10mm vertical adjustment available, but i left it at the top for now. the fender is blocked to the tire front and back, with identical blocks the right size so that the fender contacts the underside of the brace in front.



now that the fender is in position, a saddle can be fabricated for the the top of the brace, with the legs of the formed angle conforming to the radius of the fender. this piece is not symmetrical, the rear leg is always longer.



fender mount next.
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Old 11-28-2013, 09:29 PM   #2276
jdrocks OP
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snuck out to the shop for a minute to prep the fender mount for paint. it's an interesting process forming the compound curves to fit the top of the fender.

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Old 11-29-2013, 07:16 AM   #2277
jdrocks OP
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the radiator guard is the same basic stand off design i've used on previous bikes, except i'll add some gravel deflectors for the cooling fan. the fan is reliable and durable, seems to be mud resistant, but gravel caught between the housing and fan blades can jam it, causing failure. i haven't experienced the problem, but if it does happen, it will surely be at the least opportune time, in other words, when ya really need the freakin' fan.

the other little design change from the last one using the large radiator is to clearance the lower corners so they don't interfere with the Motech engine guards, not as big a problem with the small radiator.

lots of holes required, 20mm grid. by the time you drill a small diameter locator, a pilot, then a run of sizing, you'll be ready to do something else for a change.



holes deburred and chamfered both sides so the guard can be fitted to the mounts.

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Old 11-29-2013, 08:10 AM   #2278
ttpete
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Quote:
Originally Posted by jdrocks View Post
the radiator guard is the same basic stand off design i've used on previous bikes, except i'll add some gravel deflectors for the cooling fan. the fan is reliable and durable, seems to be mud resistant, but gravel caught between the housing and fan blades can jam it, causing failure. i haven't experienced the problem, but if it does happen, it will surely be at the least opportune time, in other words, when ya really need the freakin' fan.

the other little design change from the last one using the large radiator is to clearance the lower corners so they don't interfere with the Motech engine guards, not as big a problem with the small radiator.

lots of holes required, 20mm grid. by the time you drill a small diameter locator, a pilot, then a run of sizing, you'll be ready to do something else for a change.



holes deburred and chamfered both sides so the guard can be fitted to the mounts.

That would have been a perfect job for a Rotabroach (Blair cutter). They pilot on a punch mark using a spring loaded point and cut a nice clean hole.

http://www.amazon.com/dp/B000LQOCRK/...l_2mnjm2awix_b
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Old 11-29-2013, 08:26 AM   #2279
4play
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Quote:
Originally Posted by jdrocks View Post
the radiator guard is the same basic stand off design i've used on previous bikes, except i'll add some gravel deflectors for the cooling fan. the fan is reliable and durable, seems to be mud resistant, but gravel caught between the housing and fan blades can jam it, causing failure. i haven't experienced the problem, but if it does happen, it will surely be at the least opportune time, in other words, when ya really need the freakin' fan.

the other little design change from the last one using the large radiator is to clearance the lower corners so they don't interfere with the Motech engine guards, not as big a problem with the small radiator
I had the rock in the fan happen & made a mesh guard to protect the fan from the bottom. After studying it, that had to be how got in there. No issues since. Nice build!
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Old 11-29-2013, 10:56 AM   #2280
jdrocks OP
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That would have been a perfect job for a Rotabroach (Blair cutter). They pilot on a punch mark using a spring loaded point and cut a nice clean hole.

http://www.amazon.com/dp/B000LQOCRK/...l_2mnjm2awix_b

very nice kit, reasonable price, but don't have one and had to use regular old twist drills.
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