• Hi everyone,

    As you all know, Coffee (Dean) passed away a couple of years ago. I am Dean's ex-wife's husband and happen to have spent my career in tech. Over the years, I occasionally helped Dean with various tech issues.

    When he passed, I worked with his kids to gather the necessary credentials to keep this site running. Since then (and for however long they worked with Coffee), Woodschick and Dirtdame have been maintaining the site and covering the costs. Without their hard work and financial support, CafeHusky would have been lost.

    Over the past couple of weeks, I’ve been working to migrate the site to a free cloud compute instance so that Woodschick and Dirtdame no longer have to fund it. At the same time, I’ve updated the site to a current version of XenForo (the discussion software it runs on). The previous version was outdated and no longer supported.

    Unfortunately, the new software version doesn’t support importing the old site’s styles, so for now, you’ll see the XenForo default style. This may change over time.

    Coffee didn’t document the work he did on the site, so I’ve been digging through the old setup to understand how everything was running. There may still be things I’ve missed. One known issue is that email functionality is not yet working on the new site, but I hope to resolve this over time.

    Thanks for your patience and support!

Rally Fairing and other Accessories

Yeah, I guessed that there wasn't much to get. But: You forgot the pure fact that I save the complete right pipe from the Y-split to the exhaust can. And mounting material along with the exhaust can holder on the right side of the bike which will be removed. It shouldn't be that detailed regarding weight though, because I still have center stand, bash plate and crash bars mounted which weigh a lot. I'm currently thinking about throwing off the center stand.. Maybe a lighter bash plate too. We'll see. I guess regarding crash bars, there's not much weight to save.

Greetings
 
Hey guys,

most of you should now me by now (http://www.cafehusky.com/threads/tr-650-terra-from-germany.85981/ , http://advrider.com/index.php?threads/tr-650-terra-from-germany.1195413/).

In the past few month while doing adventure riding and stuff, I found some essential things I want to change on the Terra to make it even more perfect for me.

And then the idea popped up to offer you guys the parts I develop along my journey to the perfect Terra.

I photoshopped the bike how I want it to be.
Just have a look at the picture and all the details. Afterwards, I'll explain what I have in mind exactly.

View attachment 84391


Rally Fairing including Nav Tower:
I wanted to construct some rally fairing a longer time ago. I looked through different fairings offered by some of the bigger names in rally accessories. But the stuff is expensive as hell and there's no plug and play kit for the Terra. Recently, I stumbled across RadeGarage from Czech Republic. He designed a rally kit for the 690 KTM and the Husky 701 (along with some bigger KTMs). It includes a nav tower (which attaches to the steering head without being clamped down between the bearings), plexiglass windshield, fairings made of carbon or fiberglass, and two LED headlights to fit the nav tower. The whole kit is under 1000€ (http://www.radegarage.com/parts/ktm-701-fairing-kit/). In the picture above, you see the windshield and nav tower for the 701. For more detailed views, please check out the kit for the 701 in the link above. And please note: The yellow frame around the headlights is just a optional sticker.

I had some closer looks at his mounting ideas for the nav tower and thought that this should be adaptable to our bikes. There are some changes which need to be done, but it's possible.

My basic idea now is to order the KIT for the 701 Enduro and then change the needed things along with fabricating new mounts and side fairings (I want to do them with ABS plastic).

After everything is done, Rade gets the CAD files from me and then he'll produce the new, plug&play kit for the Terra. Because he doesn't want to sell the stuff without him riding it on its own, I'll be selling the stuff with him as parts deliverer (He offered that). Of course, I'll test the hell out of my prototype.

After testing, you'll be able to buy the kits. That's one of the reasons I'm posting all of this. I want to get an overview if you guys are interested in stuff like that. If not, I'll just build the stuff for me and thats it.

There will be more details further down the text. Let's get to the next point.

Handguards:

I recently got myself Barkbuster Jet guards, so that point is settled. Although I fabricated some mounts to fix them to the triple clamp. That way they could hardly move in a crash.
If there's interest, I could offer them to. The ones which are currently on my bike are just a solution for the moment, so you'll see some nice ones milled from aluminium in the future.

Custom Decals:
I just designed something which came to my mind. After figuring out the rally fairings, I'll do some measurements. I already have contact to a decal producer in germany. They use very thick, durable motocross decals, so that's what we want for adventuring.
It then would be possible that I design your decals with you. Afterwards, I'll ship them to your place.

Taller Seat:
There are basically two options for taller seats.. That's the touratech tall seat and the one from seat concept. The touratech has to many steps for my liking and the seat concept one is to wide in my opinion. Because I bought and used the lower touratech seat a while ago, I still have the original one around. I'll open it up and then form some new seat with a new cover to my likings.
Again, if there's interest.. just tell me.

Smaller Rear End:
I have a very small license plate holder compared to the original one. Still, I removed a lot of the plastic around the brake light including the lock for the seat. Now, there's just the lock cable which I tied down in a corner under the seat. Easy to operate without needing to remove the key from the ignition lock. My plan is to fabricate a nice new set up for the lower part of the rear end. Basically the black plastics under the frame. This will include some nice small brake light.

Single Exhaust:
I thought about this for a longer time now. I don't really like the offerings from GPR because as far as I can tell, they clamp an extra catalytic converter to their single exhaust system before mounting the exhaust can on top of that. Looks pretty ugly. My plan is to search for the right size akrapovic or leovince can. Then I'll contact an exhaust builder to build me a new exhaust pipe from header to can including a cat in the pipe (that's possible and often used in modern cars). Of course, this setup would save a lot of weight compared to the original setup.
You would be able to order the pipe and then get a can of your liking.

Crash Bars, Bash Plate and Offroad Tires:
Well, I already have bars and plate. Currently, I'm running Heidenau K60 Scout which are not satisfying for me. I need something more agressive. Would love some Michelin T63, but you just don't find them in germany.. So, we'll see...

One more thing is the suspension.. I'm planning to get cartridges for the front and the one from touratech for the rear..

Yeah guys, so thats it for the moment. The only future idea I have is maybe constructing additional fuel tanks in another spot than the big ass safari tanks. Rade Garage also did some for 690 and 701, so he has the know how and someone to produce them.

I'm very interested in your questions, ideas and of course in your opinion about these ideas.
If there's serious interest, please share.

If we reach a small group of people, my idea would be the following:
You would be able to preorder the stuff for a deposit (around 10-20% of the parts price). That way, I have the possibility to buy all of the stuff, develop, test, produce and so on (From next februar on, I'll be studying car technology.. so lots of spare time for stuff like that). To thank for your trust, there would be percentages off for the parts you preordered. Of course, the stuff would still be available afterwards.

Alright guys, hit the keys!

Until then..

Greetings from Germany,

Flo


Definately interested please keep me informed!! Nav tower, Decals and Screen but its not allowed to buffet or vibrate.
 
Still no proper answer from Rade. He wrote me that he's on a business trip and he'll talk to his guys yesterday.. But I didn't hear from him since..

The waiting continues.

Just wanted to make sure you guys are up to date.

And to kiwiape: My target is to get it noise free because I'm really sensitive about rattling sounds on uneven terrain.

Greetings,

Flo
 
Still no proper answer from Rade. He wrote me that he's on a business trip and he'll talk to his guys yesterday.. But I didn't hear from him since..



The waiting continues.



Just wanted to make sure you guys are up to date.



And to kiwiape: My target is to get it noise free because I'm really sensitive about rattling sounds on uneven terrain.



Greetings,



Flo



Hello risisngsun,
Wanted to ask if it hasn't been asked who is the maker of your windshield? I cobbled one up on my Terra but that would give some protection, thanks in advance Rodm850g@nc.rr.com
 
Are you talking about the windshield which is mounted with the original headlight unit? That's an universal one from louis.de.
The windshield shown above from the rally kit is made by MRA and I bought it from Rade Garage.

Alright guys,
there's finally news!
the bad one first:
My exhaust pipes won't arrive before beginning of january.. So there's time to wait on that section of the bike.
But here's what we all waited for:
The missing rally parts arrived yesterday..
Today I had a first try on without proper alignment. It stays in place with the 701 clamps, but I'll figure out proper mounting brackets tomorrow.
The handlebar moves around without touching the kit, so fitment shouldn't be an issue on our bikes.
Regarding the fender.. I'm thinking about a low fender setup. Should look cleaner, I think.


And I stumbled across new LED high and low beam with e mark. So they are certified for german roads.
Just have a look!
By the way: That's not my place, I just rented a little spot for the winter to work on the bike. I'm still searching for a proper garage.

6ebeba71-c6db-49fd-8936-27d7abd1511e.jpgd73a994b-c6b7-4cb8-a687-473c13fdb1b4.jpge96df1b9-ae9b-446f-848e-5a9102b1c7e1.jpg
Greetings, Flo
 
Thanks guys!

There's news:

Yesterday, I came up with prototype brackets along with the original clamps.
I drilled holes in the lower steering stop and in the upper construction which normally works as the steering lock.
Along with the clamps being attached to the stem, it is really sturdy now!

I took measurements and these brackets will be lasered from aluminium.

IMG_20171223_224955.jpg IMG_20171224_005521.jpg IMG_20171224_031738.jpg IMG_20171224_010434.jpg
 
Yesterday, I came up with prototype brackets along with the original clamps.
I drilled holes in the lower steering stop and in the upper construction which normally works as the steering lock.
Along with the clamps being attached to the stem, it is really sturdy now!

Both of those stops/ brackets are part of the frame.
At least in AUS, drilling holes into steering stops or any frame component is an alteration to the structure of the vehicle...and illegal, rendering the vehicle un-roadworthy.
While not being squeamish or anal when it comes to mucking around with bikes, but from a legal as well as technical/ engineering angle those holding brackets look pretty questionable.
 
Hi Flo
A few guys have broken the stop off, appears to be only TIG welded.

Every time I bang mine I think of these images
steering.JPGfix2.JPGnice MIG fix by Baddrapp

Great work so far
 
Hi Flo
A few guys have broken the stop off, appears to be only TIG welded.

Every time I bang mine I think of these images
nice MIG fix by Baddrapp

Great work so far

Agreed, looks good!

But yeah, that issue was in the back of the mind while replying above. That tower-bracket is quite a massive structure as well as being levered out quite severely. Inertia will obviously create
some high strain on those 2 under-sized mounting points. Add a few weeks of decent potholes and rough terrain/ tracks and that little steering stop will have a hard time staying in place.
Don't even mention the massive whack they'll cop in only a halfhearted stack.... with that high-mounted top-end being a pre-designed "victim".

Big kudos to Baddrapp...ANY welding on the head-stock is a damn tricky affair at best, the heat affecting the tubing, head stem bearing seats ovalling or shrinking etc etc
Been around a mate for the last 20 years who's in the bike-repair/ insurance/ restoration/ compliancing business... the stuff I get to see there is never dull :-))...
 
Alright guys,

the one thing bothering me is why people never read carefully?
These things are prototypes to figure out proper positioning and measures.
I'm already into creating data for lasering/bending the brackets from 4mm alu.
Of course, there will be proper sized bolts along with the new brackets.
I thought that is self explaining when using 'prototype'.

Both frame parts used for attaching the tower don't have any structural influence on the actual frame in my opinion.
Keep in mind, that the tower itself was designed to be attached by only the clamps.
Although the clamp which I use on the lower end are originally used as upper clamps and then they get screwed together behind the steering stem.

And, as written before, there will be also two rods coming from the radiator mounts on the frame to the holes in the lower clamps.
In addition to only weighing around 3kgs (including dash etc), I'm pretty sure it will work out.
 
Both frame parts used for attaching the tower don't have any structural influence on the actual frame in my opinion.
.

Agreed.
Only the (Oz) law makers don't agree. Nor would the German TUEV, I imagine.
If it's welded to the main structure, it's part of the frame.
Drill holes...and the frame has been modified.
Isn't there a way to mount the whole tower with clamps so that there are no alterations to the frame/ headstock?
 
I could only speak for germany, but here it is possible to get changes on non structural frame parts accepted by TUEV; for example shortened rear ends on custom builds like cafe racers.. or removed mounting brackets from parts you moved or don't need anymore in your build.. I could tell more, but you get the idea..

I was not able to come up with any satisfying construction by just clamping..
But instead, I thought a lot more today and I decided on a specific concept..
I checked the stability again without my brackets.
The clamping system itself works pretty good, but you can see on the pictures that one of the clamps was not actually intended for grabbing the stem..
More for just going around and then being connected behind it.But that's not possible on the Terra.
And just clamping is a little to unsafe for me cecause it would turn left and right pretty easy when force is applied.

Tomorrow I'll create some digital sketches to show you what I have in mind now.

Greetings,

Flo
 
I could only speak for germany, but here it is possible to get changes on non structural frame parts accepted by TUEV; for example shortened rear ends on custom builds like cafe racers.. or removed mounting brackets from parts you moved or don't need anymore in your build.. I could tell more, but you get the idea..

Similar thing here....as long as those mods are done to a bolt-on-type subframe.
(the reason I had no issues getting the chopped + modded tails of the 650 Stroms passed...they have bolt-on subframes.
Same for the bolt-on front fairing frames on those bikes (and the KLRs etc).
Modify ANY of the main frame though...and things turn nasty.
Hope, the TUEV/ DEKRA look at things differently.
 
Have you considered mounting it to the forks in stead of the frame? I know most rally fairings mount to the frame, but I actually prefer my lights to turn with the handlebars. The Britannia Composites Lynx fairing mounts to the forks and I kind of like that design.
 
Sorry guys, the second post with the screen didn't upload properly before. Here it is now

Hi Flo

Nice work your doing.

Do you think there is a chance of using the OE headlight..? IMO I like the OE shape and its a signature of the TR. The twin round is not that aesthetically pleasing or different.
 
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