But then..... I just can't help myself.
The KTM came to me with a "fender elminator". That is something that removes the part of the rear fender that extends back and down behind the rear tire and, frankly, looks ugly. When I went to install the luggage racks, I found that the fender eliminator was far from acceptable.
That part is supposed to be part of the mounting for the rear grab handles which is also where the luggage rack mounts. It needs to be a solid spacer between the tank and the rear fender, something for the grab handle bolts to squeeze.
The fender eliminator I found was either missing parts, badly designed, or both. Basically, it was just rattling around back there. So much so that a lot of powder coating had been worn away in just 600 miles.
Worse than that, it is heavy, thick wall steel with an open section design that lacks stiffness. I just had to change it.
First step was to carve out some aluminum rails the would provide correct spacing for the luggage rack mount and form a structure for a closed section aluminum shape that would mount the turn signals, tail light, and license plate. Making it a closed section made it stiff without a lot of weight.
Another part of this project was to move the turn signals because they were getting burned by the exhaust coming out of the muffler. I changed to a compact LED design and moved them up and inward to get away from the exhaust. Can you see the turn signal? It's that round knob with a shiny ring around it just below the orange tail, above the tail light (clear plastic) and the license plate. These are really cool turn signals and really bright.
Successful? Yes! The new parts are a lot lighter and also stiffer with no exhaust issues. The cost, outside of dollars, the cost was 3 weeks of workshop time. Man, I am so slow.
I've had to make other parts:
- brake tube guide
- GPS mount
- Radar detector mount
- front fender mount
So much for my good intentions of keeping this project short and easy. But that's OK. I am satisfied with the results for the most part. And the bike is a keeper, a very good match for my riding style.