Wild Dog Adventure Riding

Riding: Plan, Report and Racing => Racing Section => Topic started by: J3THRO on August 07, 2014, 10:02:53 pm

Title: WR 450 Rally NL Design
Post by: J3THRO on August 07, 2014, 10:02:53 pm
Hi All

At first I wanted to do as much of the rally conversion myself but very soon realized it will end in tears.
So I took the advice of a couple wise old dogs and made contact with Niklaus Lutzeler in Woodstock. His company is called NL Design cc and he has done an excellent job with my bike. I would recommend him to all, he is professional and very easy to work with.

The first pic is the day before I started fitting my Safari tanks and realized what a nightmare the fuel lines alone would present never mind the rally tower, electronics etc.

I picked up my bike this afternoon and Niklaus says mine is nr. 15 already and I think his business is about to explode along with the whole rally scene in SA.

I will be doing a long ride on Saturday to test everything and feel how the suspension handles the extra weight and also to see what milage I get per litre. I have about 25 litre in total now and no idea yet if this will be enough for the 270 km range stated for the Amageza.
Some stickers will still be added too.

The bike is a 2013 WR 450 F
Just off the top of my head here is a list of the main extras:

Safari front and rear tanks
Rally tower + lights (NL Design)
Rally fairing (NL Design)
Oil cooler (NL Design)
F2R Road book
ICO
Voyager GPS
Custom header pipe (Scorch)

A word of the wise to anyone hoping to the same Safari tanks: Because my bike is fuel injected and the fuel pump sits inside the tank  (bottom left) ,it took quite some modification to the tanks , the fuel pump and the hoses to get it all to work. Again Niklaus did a superb job of getting over that hurdle with NO help from Safari. After loads of enquieries from myself and Niklaus I got the idea that they weren't really prepared for the FI models yet. They just made tanks that will fit those bikes without thinking too much about the details.

Big thanks to Niklaus from NL Design cc, Chris from Flying brick and Reynard from Scorch.

Please all input will be appreciated.
I am still considering to Moose or not to Moose + Niklaus is busy with a carrier to accommodate the water + tools + medical kit  I need to carry on the bike.
At the moment running soft Mitas front and back because my riding here is mostly sand so Choice of tyres for the big day still to be determined.
Title: Re: WR 450 Rally NL Design
Post by: J3THRO on August 07, 2014, 10:07:32 pm
pix
Title: Re: WR 450 Rally NL Design
Post by: J3THRO on August 07, 2014, 10:08:08 pm
more pix
Title: Re: WR 450 Rally NL Design
Post by: J3THRO on August 07, 2014, 10:08:45 pm
last lot
Title: Re: WR 450 Rally NL Design
Post by: luckyloo on August 07, 2014, 11:29:58 pm
Cool pics J3thro. I'm stripping my wr450 07 model this weekend for a complete rebuild for Amageza.  I got the same tower still need to get all the other xtras. I was under the impression a std 12litre long range tank +safari 10 l rear tank would be sufficient but only read about the 270km range now...I suppose no chance for that on a carburettor model...you should be able to easily make it with the fi model though.  Can you share the no for nl designs would have to get hold of him for some fitments as I got my tower 2nd hand. Are you running an oil cooler in the front there?  Seems like I still have a lot of catching up to do....
Title: Re: WR 450 Rally NL Design
Post by: markdiver on August 08, 2014, 07:44:13 am
Eish, looking very good J3THRO  :thumleft:
Title: Re: WR 450 Rally NL Design
Post by: J3THRO on August 08, 2014, 08:54:59 am
PM sent luckyloo

Hope the fuel will be enough, gonna do long loop tomorrow which will include Atlantis dunes to get a better idea of consumtion.

Thanks Mark I am very happy
Title: Re: WR 450 Rally NL Design
Post by: MaxThePanda on August 08, 2014, 04:15:32 pm
PM sent luckyloo

Hope the fuel will be enough, gonna do long loop tomorrow which will include Atlantis dunes to get a better idea of consumtion.

Thanks Mark I am very happy

Well done! Lot of bikes coming together all of a sudden. I would have thought 25l would be WAAAY more than enough for 270km on a FI bike. It's not going to be all 270 in dune conditions, I wouldn't have thought, and even if it was, that's still close to 10l/100km. Surely a WR can't be THAT thirsty? Even a carb'ed bike?
Title: Re: WR 450 Rally NL Design
Post by: washer6 on August 10, 2014, 06:03:21 pm
J3thro
Hy lyk Sommer mooi man. Looks like a solid build there Bru.
Nice one
Title: Re: WR 450 Rally NL Design
Post by: Peterjohn39 on August 10, 2014, 06:53:46 pm
Cant wait to see photos of this bike with the sticker kit!

Title: Re: WR 450 Rally NL Design
Post by: pietas on August 10, 2014, 07:14:36 pm
Lovely build
Title: Re: WR 450 Rally NL Design
Post by: Cracker on August 10, 2014, 09:36:39 pm
As well as getting out of the way of the rear tanks, does the longer pipe give more torque?

Just wondering because the enduro KLX450 has a longer pipe than a KX450 and is supposedly more torquey ..............
Title: Re: WR 450 Rally NL Design
Post by: J3THRO on August 11, 2014, 08:21:02 am
Did a 260 km ride on Saturday.
Suspension handled some minor jumps just fine ; fuel looks like I will have more than enough as there is still at least 5 L left after the ride ; the pipe backfires a bit when I close the throttle but nothing too serious ; she feels n bit more responsive with the rally pipe and LOUD.
Top speed on the Voyager only 129 km/h , the standard clock shows 140 so I might drop my rear sprocket 2 teeth to a 48.
Gonna be at Eendekuil fun ride this comming weekend.
Thanks for the compliments.
Title: Re: WR 450 Rally NL Design
Post by: voorvel on August 11, 2014, 10:56:24 am
Whats the size of the front sprocket?

The extra weight + wind resistance seems to bog the 450's down quite a bit.

My semi-stock (DRD full system) 450x managed 160km/h on the gps with a flat rear tire and 14-48 gearing.
In comparison, washer's rally 450x could hardly manage 135: http://www.wilddog.za.net/forum/index.php?topic=144005.0 (http://www.wilddog.za.net/forum/index.php?topic=144005.0)
We both weigh about the same.
Title: Re: WR 450 Rally NL Design
Post by: J3THRO on August 11, 2014, 05:36:15 pm
Still standard sprockets 13 front and 50 rear.
I dont trust the Voayager yet just because I am paranoid and maybe because I am secretly hoping my speed is slightly more. Will take my zumo with next time to verify the speed.
Title: Re: WR 450 Rally NL Design
Post by: silvrav on August 12, 2014, 07:01:34 am
 :sip:
Title: Re: WR 450 Rally NL Design
Post by: LoopSoosStroop on August 12, 2014, 07:38:19 am
(http://i843.photobucket.com/albums/zz353/vdventp/b28so.jpg)
Title: Re: WR 450 Rally NL Design
Post by: Scooterbike on August 12, 2014, 10:56:14 am
I am running 14/48, think its a good balance  :thumleft:
Title: Re: WR 450 Rally NL Design
Post by: Peterjohn39 on August 12, 2014, 11:16:45 am
I see the majority of these conversions are on Honda CRF's and WR's. How much is a conversion like this cost more or less?
Title: Re: WR 450 Rally NL Design
Post by: J3THRO on August 12, 2014, 12:02:52 pm
I am running 14/48, think its a good balance  :thumleft:

Thanks Scooter I will pick up a 48 on Wednesday and fit it for Eeendekuil jol this Saturday so I can feel what its like.

What top end gps speed do you get with 13/48 combo?
Title: Re: WR 450 Rally NL Design
Post by: J3THRO on August 12, 2014, 12:13:45 pm
I am running 14/48, think its a good balance  :thumleft:

Thanks Scooter I will pick up a 48 on Wednesday and fit it for Eeendekuil jol this Saturday so I can feel what its like.

What top end gps speed do you get with 13/48 combo?

Sorted just read your build , damn thet rally light looks good. If I can get 140 km/h ,Im happy. I am not looking to break any records. FINISHFINISHFINISH
Title: Re: WR 450 Rally NL Design
Post by: voorvel on August 12, 2014, 12:27:11 pm
Dropping 2 on the rear makes ~5km/h difference
Title: Re: WR 450 Rally NL Design
Post by: Scooterbike on August 12, 2014, 01:52:33 pm
14/48 gives me 140 on the gps.
that makes for easy cruising at 110.
Title: Re: WR 450 Rally NL Design
Post by: tau on August 12, 2014, 07:19:37 pm
14-48 and she will do 151 km/h . When I was at NL desgns collecting the GSA after a 21" conversion I had a look at your bike. Very neat. My 2013 Wr450 makes me smile condtantly.


Sent from my iPhone using Tapatalk
Title: Re: WR 450 Rally NL Design
Post by: J3THRO on August 13, 2014, 09:59:47 am
Great Tau 14 - 48 it is then
Title: Re: WR 450 Rally NL Design
Post by: J3THRO on August 15, 2014, 03:11:53 pm
Ok 48 fitted and top speed went from 127 to 138 , still waiting for my 14 front sprocket.
As far as fuel consumtion goes, I finally have some stats.
I used 23,5 l and did 307km. All measured with the gps which I think is acurate. So about 13km/l
This included about 20 km soft sand , about 30 km cruising on tar and fast gravel the rest of it.
Title: Re: WR 450 Rally NL Design
Post by: Scooterbike on August 15, 2014, 03:32:14 pm
Let me know when you want to do a long (day) trip again.
Title: Re: WR 450 Rally NL Design
Post by: J3THRO on August 15, 2014, 03:42:15 pm
Sounds good Scooterbike. I will be at the Eendekuil fun ride tomorrow.

I will definately let you know.
Title: Re: WR 450 Rally NL Design
Post by: J3THRO on August 21, 2014, 04:12:18 pm
Dropped off the fairing to get plastic dipped blue. It took a bit of punishment in the bush at the Eeendekuil ride + it is a bit brittle on the edges.
I also picked up a moose for the front at Dirt Rider who said he has plenty of stock left. Eddie2Race is waiting for stock , I believe.
Title: Re: WR 450 Rally NL Design
Post by: MaxThePanda on August 22, 2014, 10:59:39 am
Dropped off the fairing to get plastic dipped blue. It took a bit of punishment in the bush at the Eeendekuil ride + it is a bit brittle on the edges.
I also picked up a moose for the front at Dirt Rider who said he has plenty of stock left. Eddie2Race is waiting for stock , I believe.

Tell us more about the plastic dipping process?
Title: Re: WR 450 Rally NL Design
Post by: J3THRO on August 23, 2014, 11:37:06 am
Hey Max

I was under the impression the thing gets dipped in the plastic but that is not the case. It is a layer that gets sprayed on but I wont recommend it because it is very fragile I have rubbed it off on the corners already.

Title: Re: WR 450 Rally NL Design
Post by: BlueBull2007 on August 24, 2014, 01:49:09 am
Thats a nice looking build. :thumright:

If youre on a carbed bike 10K/l is not that unusual when racing in Sandy conditions. Remember a 8-15km nav error can hurt your fuel range as well ;D

Yamaha and Hondas are most often converted into rally bikes because they´re the cheapest. Theyre also very realiable machines. Not sure what it costs these days, but I will be racing my 2009 WR again. I got 153km/hr on the gps alongside Tau´s bike in 2012...so maybe the new bikes are getting slower.
:peepwall:

Agree that 14/48 is good, but take an extra chain slider with. :deal:



Title: Re: WR 450 Rally NL Design
Post by: White Rhino on August 24, 2014, 04:49:46 am
The conversion does look very cool.  :thumleft:  :thumleft: The tower looks the biz. I got a similar consumption to you (13l) with mixed terrain on my 2009 model. That motor runs soooo nicely. :biggrin:
Title: Re: WR 450 Rally NL Design
Post by: Rolling Stone on August 02, 2015, 04:16:16 pm
Hi guys
time to revive this thread again.
My10 liter tank has arrived from Safari and I need to get a header sorted.
I have the 20o7 carb model.
Does anyone have a modified header or some advice how to go about getting the header sorted?
I am also looking for the following
spare reg and stator ( vapor model)
Spare rear hub (seems like my yz hub will not fit the wr)



Title: Re: WR 450 Rally NL Design
Post by: BlueBull2007 on August 02, 2015, 11:08:13 pm
Jethro are you in again this year?
Title: Re: WR 450 Rally NL Design
Post by: Rolling Stone on August 03, 2015, 07:41:05 pm
Hi guys
time to revive this thread again.
My10 liter tank has arrived from Safari and I need to get a header sorted.
I have the 20o7 carb model.
Does anyone have a modified header or some advice how to go about getting the header sorted?
I am also looking for the following
spare reg and stator ( vapor model)
Spare rear hub (seems like my yz hub will not fit the wr)

come boys I need advice.
can I modify my current header, was told that they are difficult to weld once used
I have a guy that can weld stainless and alu, not sure what the header is made of
Title: Re: WR 450 Rally NL Design
Post by: Gee S on August 04, 2015, 01:31:26 pm
It is normally made of mild steel. Stainless will work but Alluminium not. You should be able to buy the correct pipe at you local exhaust shop.
Title: Re: WR 450 Rally NL Design
Post by: J3THRO on October 04, 2015, 07:02:50 pm
Jethro are you in again this year?

Hi BB

Starting a whole new build next month. Husky 501 for 2016 so here I am stalking the racing section again.
I could not do 2015 as work was a bit quiet and bucks scarce. Hopefully I can manage to make it to 2016 Geza. I will be malle motoing with all the usual suspects from western cape. Rudi is on an XR 400 for 2016 and hopefully Claude + Gerrit are keen for 2016. I know Nik is also in but not sure if he will do mm or team entry.
Got the navigational rally box ticked in 2014, now hopefully I can tick the malle moto box and after that I want to complete 1 international rally before hanging up my rally boots.
Title: Re: WR 450 Rally NL Design
Post by: Xchallenge on October 04, 2015, 08:46:50 pm
nice!