KTM 640 Adventure Rally Build

[WesleyDRZ400]

Fitted this in the end, just need to bolt link pipe back on as unsecure and then weld 2 small flat bars from side of subframe to retain link pipe and silencer. I think it looks OK, it's lightweight compact and road legal.
It's not to low down to cause hassle and not to high up to interfere with soft luggage or ear drums

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[daveuprite]

Yeah that looks good. Love the way it's coming together.

[WesleyDRZ400]

Yeah that looks good. Love the way it's coming together.

It's starting to come along now, hopefully all welding and grinding complete this weekend.
Putting flat bar welded to side brackets on frame like this one and will put rubber heat resistant damping washers to allow a little flex on silencer and link pipe so it won't crack welds on frame/side
brackets

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[WesleyDRZ400]

Grinding a few snag areas, decided not to cut the front tank lugs off but to rather thread a long bolt in from behind and cut it so it's slightly countersunk and weld the back. So basic just a stud sticking out of lug that I will fit the side tank onto the stud and put a nut on top. Better idea I I think. See lug in photo

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While the 660 airbox is off check out the size difference compared to the standard 640 box

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[WesleyDRZ400]

Also decided to tidy garage before I carry on

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[WesleyDRZ400]

Bash plate toolbox idea?

Will need to get a aluminium back to put on back of toolbox and then bolt to bash plate abit like this

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[WesleyDRZ400]

Not to much progress as hoped.

Well decided after threading a stud in front lug that holds the side tank that idea was not suitable as stud snapped while overtighting it which if I was going to weld stud in would not be good if snapped. Will just drill hole for stud/bolt and if ever snaps have spare with me. Side tanks are secured via 3 connections so pretty secure still if one snapped

Went for angle bar sides

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Will need to trim once I drill hole so it will not fret on tank

[WesleyDRZ400]

Exhaust brackets over engineered I think but at least should not break

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Will trim up with grinder once I drill the holes, will have rubber damper washer fitted between once finished

[WesleyDRZ400]

Decided on this for rear shock adjuster, will be secured by a exhaust clip to frame in the slot with tape on

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[WesleyDRZ400]

That's all the welding on the frame completed, just need to tidy up the welds and drill holes where required and trim up with grinder a few areas. Hopefully should get subframe and fairing sprayed end of week