KTM restoration

DAMN maintenance and repair thread; including Farkle Fests! :boohoo:
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Wingfixer
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Re: KTM restoration

Post by Wingfixer » Tue Feb 21, 2017 8:09 pm

Skinny-J wrote:
Tue Feb 21, 2017 9:34 am
Wingfixer wrote:
Tue Feb 21, 2017 7:40 am
I did a complete restro on the DRz a few years ago. Tore it down to the frame and powder coated it RED! It was a pretty rewarding project but since then it has become a bit of a garage princess.
Painting it red still won't make a Suzuki as fast as a Honda.... :shrug:


BTW, nice write up Jed; good luck with the build. :thumbup:
I don't recall seeing your Honda in front of my "RED" DRz all that often. :deal:
F*** work.
Ride motorcycles.

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juddspaintballs
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Re: KTM restoration

Post by juddspaintballs » Wed Feb 22, 2017 11:44 am

I had my wife go to Harbor Freight while I was working yesterday and pick up a tap and die set since I didn't have any metric taps at all. I got a free tape measure too!

I was lacking thread cutting oil. I read on Practical Machinist that bacon grease is a good substitute for thread cutting oil (way better than WD-40, PB Blaster, bearing grease, etc.). Fortunately, we keep a container of bacon grease in the fridge for cast iron cooking, so I scooped a spoonful onto a paper towel and took it to the garage for tapping a few holes.

I used the M6 tap to tap the gas tank mounting stub and then I welded it onto the frame perpendicular and square like the original.

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I also cut up a piece of metal and made two tabs that I could weld to the frame for the skid plate to mount to rather than using the aluminum clamps around the frame that destroyed the paint on it over time. They look uneven because they are. The holes in the skid plate are offset for some reason. The M8 tap worked very well for tapping the holes in the tabs. The bolts I'm using to show it assembled are not the bolts that I'll be using on final assembly.

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Now, off to the powder coating place.
Jed Gregory
KTM 450 EXC

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juddspaintballs
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Re: KTM restoration

Post by juddspaintballs » Tue Feb 28, 2017 9:36 am

$180 for sandblasting and powder coating.

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I have my modified muffler internals all pieced together, now I just need to repack it. There will be a screen in the muffler for spark arresting. I bought a piece of perforated metal pipe for the internals and I welded the ball and socket end on one side and made a slip over joint on the other side. I'll wrap it in screen and then muffler packing and I should have a quieter than stock exhaust for about $40. I still need to strip and paint the can in VHT paint.

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Jed Gregory
KTM 450 EXC

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Bucho
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Re: KTM restoration

Post by Bucho » Tue Feb 28, 2017 9:27 pm

Looking real nice Jed
Suzuki DR650
Beta Xtrainer

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juddspaintballs
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Re: KTM restoration

Post by juddspaintballs » Sat Mar 04, 2017 10:05 pm

Brent found a desert race 3.5 gallon tank on eBay for me for a couple hundred bucks less than the 4 gallon tank I wanted to buy from Safari. The upside is that the desert race tank is a factory KTM part. I'll probably buy a new petcock for it and clean it up a little bit so it looks new. To go along with the new tank, I found a brand new OEM tank for this year bike that fits best with the desert race tank. My stock seat would have a gap at the bottom between the tank and the seat.

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I got another email from the engine guy (Dave Hopkins) today. The crank is back together, it sounds like I needed a new connecting rod, the bottom cases are back together, the piston is in, the cylinder recoated and installed, and he's just waiting on the valves to come in before he buttons it up and ships it back to me. He'll probably want a lot of my dollars. Fortunately, I just finished up a pay period with 72 hours of OT on it (that's 168 hours of work in 2 weeks, you lazy bastages!).

I'm really looking forward to having this bike back together exactly the way I want it.
Jed Gregory
KTM 450 EXC

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beejaytee
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Re: KTM restoration

Post by beejaytee » Sat Mar 04, 2017 11:22 pm

This bike is gonna look so good.


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2007 525 exc
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juddspaintballs
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Re: KTM restoration

Post by juddspaintballs » Tue Mar 07, 2017 12:03 am

I splurged and spent way too much money, but I bought a semi-used Big Gun Mike Lafferty exhaust system for my KTM. The header pipe is new and converts it to a single pipe instead of dual pipes like stock. Supposedly it's ceramic coated, too. The muffler is slightly used, but appears to be in decent shape according to the description and pictures. There's a couple different silent inserts for it, too.

I wound up needing a new header, so this solved the muffler and header problem together and it cleans up the dual pipe look.

Here's a picture of the kit before it arrives here:

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Jed Gregory
KTM 450 EXC

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Madizm
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Re: KTM restoration

Post by Madizm » Tue Mar 07, 2017 7:25 am

Looking awesome. I'm jealous. Mine next??
2011 KTM 450 six days- parting out
2005 Honda CRF250f

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juddspaintballs
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Re: KTM restoration

Post by juddspaintballs » Tue Mar 07, 2017 8:38 am

I'll gladly help you, but my requirement is that it's got to be in my garage and you have to work on it too.
Jed Gregory
KTM 450 EXC

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juddspaintballs
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Re: KTM restoration

Post by juddspaintballs » Sun Mar 12, 2017 5:18 pm

My exhaust might be lost in the mail. It hasn't moved in days and it was supposed to arrive on Friday. :dry:



And I finally got an invoice for the power plant. I should see it in a week or so.

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Jed Gregory
KTM 450 EXC

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