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Old 06-13-2013, 09:51 PM   #166
ktmklx
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Looking very nice. Are you bending your own ex tubes or buying pre bent? Where did you get the nice exhaust flanges?
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Old 06-13-2013, 09:57 PM   #167
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Originally Posted by ktmklx View Post
Looking very nice. Are you bending your own ex tubes or buying pre bent? Where did you get the nice exhaust flanges?
I buy mandrel bent 1 5/8" 90's for the midpipe and 1 3/8" 180's for the headers. I cut the flanges off the original Versys headers. I wish I could find a source for the flanges but haven't had any luck so far.
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Old 06-13-2013, 10:09 PM   #168
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I think the black frame looks great on a green KLR

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Old 06-14-2013, 09:15 AM   #169
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Ya buddy, that looks very nice! The headers look pro too!
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Old 06-16-2013, 03:29 AM   #170
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Man!... that is really looking nice!

Powder coating the frame black was a great idea. Really gives it an aggressive assault vehicle look.

Can't wait to do some assaulting with it!
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Old 06-18-2013, 10:01 PM   #171
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Wonderful looking build! +1 on Rick and Cogent Dynamics shock work. Your work does have a professional quality look.
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Old 06-21-2013, 09:49 AM   #172
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Hey....I think I have seen that green Versys before...
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Old 06-23-2013, 06:11 AM   #173
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Updates

Haven't had much time to post, down to 12 days to finish, but thought I'd at least upload some pictures.












Airbox connector build. Love my new 55mm hole punch, from England.






Homemade bender in action


Done


When the intake manifolds are installed upside down they don't line up with the port on the head, so I elongate the bolt holes.



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Old 06-23-2013, 06:20 AM   #174
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Originally Posted by TxMauler1 View Post
Hey....I think I have seen that green Versys before...
I would think so. I got to ride it once after I left your place.
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Old 06-24-2013, 11:54 AM   #175
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Wow, its really cool to see how the KLRsys magic happens!
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Old 06-24-2013, 12:06 PM   #176
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Wow, its really cool to see how the KLRsys magic happens!
Shoot, I wish it was magic. I'd be done by now.
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Old 06-24-2013, 01:40 PM   #177
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Shoot, I wish it was magic. I'd be done by now.
LOL
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Old 06-25-2013, 09:13 AM   #178
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Quality takes time ...
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Old 06-29-2013, 09:16 AM   #179
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Hows the Magic coming along?
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Old 06-29-2013, 10:08 AM   #180
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It's coming along, not as quickly as I'd like, but making progress. My real job has been invading my building time.

Made a brake pedal, at least half of one.




shifter



Bell crank and cable mount




Starting to look like a bike that might be able to travel in, uh, 13 days!



Test fitting the luggage, making sure the shock preloader clears the panniers.



Today's projects, plumb the fuel system and start on the wiring.
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