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Author Topic: Project Meerkat: Converting the DRZ in the ultimate lightweight Adventure bike  (Read 4998 times)
mtbbiker
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Project Meerkat: Converting the DRZ in the ultimate lightweight Adventure bike on: December 13, 2011, 10:32:23 pm

Let me first start at the beginning. I always wanted a bike that I can play with at the weekend but also take on a longer trip.
The following is the start of an attempt to create the ultimate Lightweight Adventure Bike that fit my requirements.
Since there is nothing on the market (In my opinion that offers this) this makes me the Leader in that market  mwink
(Note my definition of lightweight Adventure Bike is anything smaller than 500cc so Yes the KTM Oryx does NOT count! )

PS: Since the KTM guys call their 690 the Oryx, I decided to also give mine an African flavour, so I called it the Meerkat Roll Eyes

The main reason to start this project is to make the ride more comfortable, doing plus 110 kpa on a stock standard DRZ for more than 100km is NOT fun.
So I decided it needs a fairing, like what is used in the Dakar. View thread for more info: http://www.wilddog.za.net/forum/index.php?topic=54687.msg1709922#msg1709922

So lets get to it

The plan is to ultimately build the final product out of fibreglas (Or even out of PVC sheeting)
The biggest challenge at the moment is to find the correct lights.
I am looking at 90mm Hella driving lights - they off a twin combination with Low beam and high beam. The problem is that they use an H9 bulb that is 65W. The standard DRZ is H3 and 55W.
The ultimate solutionn will be HID. If you have any ideas or solutions please let me know.

It all started with a Paper template.


I then traced this onto Komatex sheets, cut them out and started bending:


Build the first prototype

mock-up view


Close up of second prototype


I then took it for a test ride to find out if there is any protection from the wind


More pictures

Fitted the perspex screen



TODO:
1. Fabricate the bracket and fit to frame ( I have a bolt on solution!)
2. Fit lights.
3. Paint the fairing (Please help with ideas!)
4. Complete the fibreglas mold

As I progress I will post and give you all an update.

Any help with the light will be appreciated !
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Project Meerkat:DRZ rally build http://www.wilddog.za.net/forum/index.php?topic=86025.0
braamn
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Re: Project Meerkat: Converting the DRZ in the ultimate lightweight Adventure bike Reply #1 on: December 13, 2011, 10:34:32 pm

Wow that could be a really cool project, going to be a cool result!!
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Re: Project Meerkat: Converting the DRZ in the ultimate lightweight Adventure bike Reply #2 on: December 13, 2011, 10:43:41 pm

I reckon the lights off a Madass 125 will be perfect for this application..



Maybe you can find out the price on a unit from the SA importer..

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2013 KTM Duke 690 R
1962 Lambretta Li 150(Sold)
1973 Honda MT 250 Elsinore (Sold)
1982 Honda Cx500 Brat Style (Sold)2012 Moto Guzzi V7 Racer (Sold)
2003 Ktm 300 EXC (sold) 1999 Yamaha Wr 250 (Sold) 1996 KTM 625 Adventure (sold)
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Re: Project Meerkat: Converting the DRZ in the ultimate lightweight Adventure bike Reply #3 on: December 13, 2011, 10:44:51 pm

apologies for the multiple posts..

here is a close up..



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2013 KTM Duke 690 R
1962 Lambretta Li 150(Sold)
1973 Honda MT 250 Elsinore (Sold)
1982 Honda Cx500 Brat Style (Sold)2012 Moto Guzzi V7 Racer (Sold)
2003 Ktm 300 EXC (sold) 1999 Yamaha Wr 250 (Sold) 1996 KTM 625 Adventure (sold)
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Re: Project Meerkat: Converting the DRZ in the ultimate lightweight Adventure bike Reply #4 on: December 13, 2011, 10:50:49 pm

I reckon the lights off a Madass 125 will be perfect for this application..



Maybe you can find out the price on a unit from the SA importer..



DONT!!
I had a brief rush o blood to the head and bought a madass, the lights are shite, they popped out from wheelying Huh?
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DJ
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Re: Project Meerkat: Converting the DRZ in the ultimate lightweight Adventure bike Reply #5 on: December 14, 2011, 07:22:46 am

Hey mtbbiker,

Your DRZ "Meerkat" looks really great, awesome job.  icon_thumleft

How did your test run go?
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mtbbiker
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Re: Project Meerkat: Converting the DRZ in the ultimate lightweight Adventure bike Reply #6 on: December 14, 2011, 07:23:11 am

I reckon the lights off a Madass 125 will be perfect for this application..



Maybe you can find out the price on a unit from the SA importer..


I have the serial numbers of HB and LB Hella lights and they look very similiar. I will visit a few part stores today Grin

DONT!!
I had a brief rush o blood to the head and bought a madass, the lights are shite, they popped out from wheelying Huh?

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Project Meerkat:DRZ rally build http://www.wilddog.za.net/forum/index.php?topic=86025.0
mtbbiker
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Re: Project Meerkat: Converting the DRZ in the ultimate lightweight Adventure bike Reply #7 on: December 14, 2011, 07:26:51 am

Hey mtbbiker,

Your DRZ "Meerkat" looks really great, awesome job.  icon_thumleft

How did your test run go?
Even though its just a prototype and not yest solidly fixed to the frame it worked very well. I currently have a Dakar screen fitted that works very well in keeping the wind of your chest. This screen is a bit higher icon_thumleft and a bit more forward which is a bonus for doing technical stuff - You don't hit the screen with the helmet when you are standing on the pegs  Wink
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Project Meerkat:DRZ rally build http://www.wilddog.za.net/forum/index.php?topic=86025.0
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Re: Project Meerkat: Converting the DRZ in the ultimate lightweight Adventure bike Reply #8 on: December 14, 2011, 07:31:17 am

Cool job, this is going to be interessting  icon_thumleft
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Re: Project Meerkat: Converting the DRZ in the ultimate lightweight Adventure bike Reply #9 on: December 14, 2011, 07:32:00 am

Awesome!! Thanks for the feedback.

Definately would want to upgrade my DRZ to a Meerkat!!
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Re: Project Meerkat: Converting the DRZ in the ultimate lightweight Adventure bike Reply #10 on: December 14, 2011, 07:33:11 am

Looks like a nice project, keep posting.
How does the cost of building a fairing compare to buying one?
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Re: Project Meerkat: Converting the DRZ in the ultimate lightweight Adventure bike Reply #11 on: December 14, 2011, 08:15:08 am

Looks like a nice project, keep posting.
How does the cost of building a fairing compare to buying one?
So far only based on material used for the protype less than R1500. Lights will probably be in the region of R1100 if I use a brand like Hella. I am not sure what fibreglas materials will cost. Buying a fairing wasn't an option. The only one's I could find was over R10K. Superfoxi here on the forum have KTM640 fibreglas fairing that is in the region of R2500-3000. Then you still have to source lights and the frame bracket
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Project Meerkat:DRZ rally build http://www.wilddog.za.net/forum/index.php?topic=86025.0
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Re: Project Meerkat: Converting the DRZ in the ultimate lightweight Adventure bike Reply #12 on: December 14, 2011, 08:27:44 am

Did you look at the lynx fairing?

Shjo so about 3k verse 10k is a no brainer, Besides a custom job always looks the part, are you going to get a long range tank at any stage? That may affect the fairing design.

I have a fairing but am going the reverse route by getting rid of the accursed rattling monster
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Re: Project Meerkat: Converting the DRZ in the ultimate lightweight Adventure bike Reply #13 on: December 14, 2011, 08:29:21 am

Wow, your skills (not to mention your problem-solving ability) is impressive - and you're still only at the mock-up/prototype stage.

Serious respect and good luck.  icon_thumleft
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Re: Project Meerkat: Converting the DRZ in the ultimate lightweight Adventure bike Reply #14 on: December 14, 2011, 08:34:43 am

Subscribed
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DeepBass9
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Re: Project Meerkat: Converting the DRZ in the ultimate lightweight Adventure bike Reply #15 on: December 14, 2011, 08:39:26 am

Quote
I am looking at 90mm Hella driving lights - they off a twin combination with Low beam and high beam. The problem is that they use an H9 bulb that is 65W. The standard DRZ is H3 and 55W.

Is there not something available in LED which draws less power? YOu can definitely replace your rear light with LED to gain a few watts of spare capacity.
Last Edit: December 14, 2011, 08:43:56 am by DeepBass9 Logged

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Re: Project Meerkat: Converting the DRZ in the ultimate lightweight Adventure bike Reply #16 on: December 14, 2011, 08:42:42 am

Great project - definitley subscribed!
Pity the fairing can't me made from the same sort of "plastic" as the standard panels - it's really tough and when (if) you drop it, you hardly notice it.
With fibreglass, you stand the risk of cracking/breaking it.
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Re: Project Meerkat: Converting the DRZ in the ultimate lightweight Adventure bike Reply #17 on: December 14, 2011, 10:58:17 am

Subscribed
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Re: Project Meerkat: Converting the DRZ in the ultimate lightweight Adventure bike Reply #18 on: December 14, 2011, 11:00:50 am

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Re: Project Meerkat: Converting the DRZ in the ultimate lightweight Adventure bike Reply #19 on: December 14, 2011, 02:23:30 pm

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