HONDA AFRICA TWIN RD07 RALLY BUILD ________________________ This is about a "transformation " from a legendary old bike to a new adventure bike! Follow us on our social media and stay tuned on all our projects : Instagram -> https://www.instagram.com/perfectfairings/ Facebook -> https://www.facebook.com/PerfectFairings ________________________ 01.The Bike The bike which we received and asked to make it looks like a new rally bike was a Honda Africa Twin RD07 1993. It was a great bike to work and make a nice rally bike. The bike we received was a hard used bike almost 30 years old , so we start working on it on several designs but the final decition was taken from the bike owner . The bike was bought for a reason , a nice rally projct . The "Mata De Aqua Project " https://www.instagram.com/matadeaguaproject/ ________________________ 02.The PROJECT First thing we had to do was to remove all plastics and headlights including the rear brake light . Then we have removed the chain guard,radiator guards and the aluminium frame covers. New parts designed in order to replace the old parts. -Radiator protections -Chain guard -Frame covers Once we finished with the design it was the time to place the new goodies on the bike ! *In the main time navigation tower was ready to take place on the bike ! Next big step was to install the navigation tower , it was easy enough as the Africa have a bracket from factory to hold the headlights and clocks ! Navigation tower is now on the bike so we can start making the new side panels !! "Navigation tower is the main part which holds the headlights, speedometer and also have brackets for the new windshield ." Side panels ! This maybe sounds easy to do but its a very slim line between the fail and success ... First step was to produce a pair of fiberglass standard side panels , like the OEM . We made the fiberglass panels and we start drawing new designs .. The original idea was to keep the air intakes on the side panels ,this was not good at all in real life :) . We start cutting the standard side panels and with some magics the first prototypes getting a nice shape ! The result was better than the one with the air intakes on the side panels . The whole bike was looking "aggressive rally" ,new side panels fits like a glove on the bike without any modifications and we are really happy !! Next job to do was to fix a nice tail / lisence plate holder .. As we had something from our previous projects we decided to go with it . Few modifications in order to get a great fit on the standard rear fender mounting points . Yes !! The new fender was really nice , nice lines which follow the bike and doesnt look like an extra part ! ________________________ 3.The Rally Bike All parts are ready , tested and already on the bike ! Lets see what we have .. -Rally side panels -Navigation Tower -Radiator protections Aluminium -Frame covers -Chain guard -Rear fender Rally style Next step was the roadtest and feedback :)
By DNA Filters credits : https://www.drr022.com/ The Beauty of advanced kinematics! _______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ …and this is how the idea of DRR-022 was born. The DNA Real Racer. The creation of a race-ready motorcycle with dimensions based on the Moto3 category of Moto GP equipped with an unconventional front system and manufactured only with materials and parts straight from the world championship. _______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Back in 2019, a new addition to the R&D team, Alexandros Maidis,a passionate engineer who is sharing the same passion about motorsports with Dino and Mario Nikolaidis, brought with him a portfolio provided with research on an alternative front system, based on the double wishbone suspension of Norman Hossack, optimized for lightweight motorcycles and a history of designing and manufacturing a couple of prototypes carrying a variation of such a set up. The last two years, owing to the pandemic’s lock down that has as a result the lack of business trips and exhibitions, lead the R&D team of DNA Filters, to thousands of hours of designing new products and innovative solutions for its production lines but most importantly gave them the opportunity to develop the new big thing… a lightweight race bike that will feature almost frictionless front and rear suspension! The target was clear. Near zero friction at all moving parts of the suspension, total weight less than a modern Moto3 bike but most importantly precisely engineered and manufactured. And the R&D team set the main features for this project: • Double wishbone front suspension • No use of ball joints, only preloaded double row ball bearings • Fully adjustable geometry • Special intake system using SLS & FDM 3D printing technology • Lightweight structure CNC Machined from billet aluminum • Moto3 spec parts & dimensions • As close as possible to 1:1 power to weight ratio • Carbon fiber subframe & fairings This project was set to be an extremely demanding engineering task putting human and machines to their limits with the highest quality and precision standards. As DNA filters always aims in all of its engineering fields. _______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Unconventional approach Already, modern telescopic forks feature good rigidity, acceptable static and dynamic friction. The target for the DRR-022 is almost zero static and dynamic friction. So it was clear from the beginning, the only way to go was by using nothing but ball and needle roller bearings in any joint for both front and rear suspension. No ball joints here! Another great aspect of this front suspension set up, is the fact that its kinematics are completely adjustable, meaning that the mechanic could change its characteristics in a couple of minutes, for instance, the percentage of diving during braking, just by inverting a couple of pivot points. Furthermore this front set up is designed in such a manner that provides a greater trail variation throughout the wheel travel aiming for the maximum stability during acceleration and high speeds without any compromise at changing direction. _______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Implementation The fork is attached to the frame via two asymmetric CNC machined wishbones made from 7075 T651 aluminum. The bottom one is responsible for actuating the front shock absorber via a pull rod, giving a travel ratio of 2:1. Double row, preloaded ball bearings, are used for every single joint of this setup. From steering to suspension movement, the friction is minimized everywhere. The steering input from the rider to the fork is transferred via a scissor link, that is also using preloaded ball bearings. The goal for this setup was to eliminate every bit of play, from the assembly and at the same time, maintaining rider’s input to the fork and vice versa, giving as much feedback as possible. A unique shock absorber is developed by Hyperpro for this application, fully adjustable in rebound and high/low speed compression. Additionally linear or progressive springs can be used. _______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Lightweight The chassis has a twin spar layout and is using the engine as a structural member. It consists of six CNC machined parts made out of 6082 T651 aluminum, welded together. With its 3mm wall thickness and its specially designed internal ribs achieves the preferable rigidity weighing only 3.6 kg. The rear subframe is made from carbon fiber. The front subframe is machined from 6082 T651 aluminum and apart from holding the steering assembly is also the top cover of the airbox. Despite the plethora of parts that constitute the front suspension, the R&D team managed to achieve a very low overall dry weight that does not exceed 75 kilos. _______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Breathing One of the key components of this project is the ram air intake. The induction of the engine is designed in such a way that channels the air to a specially designed panel filter, directly from DNA’s racing division. The intake system consists of two basic components: The intake and the airbox. Both of them are 3D printed and thus there were no constraints about the design and manufacturing process. The intake is 3D printed from Nylon-CF, manufactured inhouse and it also works as the upper fairing mount which means that it has a lot of structural rigidity. The airbox is also 3D printed made from PA12 Nylon powder, with Laser Sintering technology. One of its key features is the fact that it has specially designed channels to guide the throttle cables, that are traveling through it, without any opening that could allow debris to be “sucked” from the engine. _______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Acceleration A brand new Yamaha YZ450F engine was chosen to power “The Unconv3ntional”. It is a race proven engine with a power output close to a modern day Moto3. The engine is precisely tuned in order to improve top end power output without compromising on reliability. A stand alone ECU took the place of the OEM one, in order to match the needs of the DNA forced intake system and the Akrapovic exhaust that is bespoke built for this bike. _______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Deceleration The braking system of this lightweight racer is directly derived from the latest Moto3 bikes. Calipers and master cylinders came from Accossato racing series. The front brake assembly uses a twin rotor layout with rotors of 220 mm in diameter -manufactured inhouse- and two twin piston radial CNC machined calipers. The radial master cylinder in the front is adjustable to 17/18/19mm of leverage.The rear radial caliper, like the front, is CNC machined twin piston and the rotor is 200mm in diameter. _______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Telemetry In a project like this monitoring everything is mandatory. Especially during the development. Thanks to the wiring loom custom-made by our partner Plex Tuning, every key aspect of this motorcycle will be monitored. Suspension position, steering position, accelerometers, GPS and brake pressure are few of the inputs going to the telemetry, plus full engine data. Everything is logged and displayed in the SDM-330 dashboard. _______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ DRR-022 Specifications Engine: Single Cylinder Racing Engine Capacity: 449.7 CC Engine Type: Water Cooled Bore/Stroke: 97mm/60.8mm Compression Ratio: 13.0:1 Valve Train: 4 Overhead titanium valves Fuelling System: EFI,Keihin 47mm Throttle Body Transmission: 6 speed Clutch: Wet multi-plate clutch Final Drive: Chain Frame Type: Twin spar,Aluminum CNC machined Sub-Frame: Carbon Fiber Wheelbase: 1280 +/- 10mm Fuel Tank: Aluminum Fuel Capacity: 11.8L Weight: 75kg dry weight Air Induction: 3D printed FDM NYLON-CF Ram-air & 3D printed SLS PA12 air box with DNA racing filter Exhaust: Akrapovic full titanium custom made for the DRR-022 Front Suspension: Hyperpro 3D Shock race spec custom made for the DRR-022 Rear Suspension: Hyperpro 3D Shock race spec custom made for the DRR-022 Front Master Cylinder: Accossato Moto3 racing Rear Master Cylinder: Accossato Moto3 racing Front Brakes: 2 x 220mm disks, 2 piston Accossato Moto3 Radial billet calipers Rear Brake: 1 x 200mm disk, 2 piston Accossato Moto3 Radial billet calliper Considering all the things above we believe that the end result is nothing short of amazing. Today, here in Milano, at Eicma 2022, we proudly present to you one of the most challenging projects that we have put our hands on, showing on a global level, what our company is capable of. Firstly, Dino Nikolaidis, co-founder of DNA Filters, using his racing experience, engineering and machining skills and his knowledge around materials like aluminium, titanium and stainless steel contributed decisively to fine tune the project setting the standards in some of the most critical parts and the overall manufacturing quality. Next, Mario Nikolaidis, managing director of DNA Filters, through his valuable experience in managing and his modern communicative point of view, is the person who divided the duties and set the deadlines, coordinating the team, aiming to the best results. Besides, the right orchestration of a team for a project like this is equally important with the project itself. Alexandros Maidis, the man behind this project, was responsible for intriguing the team with his vision in a first place, remained open for new ideas, suggestions and advices concerning his design. Always there, contributing to anything he was asked and ready to advice and consult, kept the level high. _______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Conclusion The team behind this operation is the whole company of DNA Filters. From the major contributors of R&D team to the procurement department. From the marketing division to the production line one thing is for sure, that without them, the end result wouldn’t be one that lives up to DNA’s standards. Design & Engineering excellence! We hope that you will enjoy The Unconv3ntional. _______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Gallery
Our best seller fairing kits for KTM 690 Enduro 2008 2018 are nearly 7 years on the market ,with great feedback and the most important no failures!! During the years we have update these kits from scratch and we made them even better . Why choosing this kit ? Let us explain why in few lines .. -First of all we use OEM KTM windshield - headlight cover and also the clear protection for the headlights ,these parts was designed for the KTM 450 Rally bike (yes the one which participate on the Dakar race) so there are no better thing than a great OEM product ! -The lights are MOTORCYCLE street legal lights ,made by Hella a top brand company . Also the position light are OEM Hella not a simple noname light .. -Headlights wiring harness are made from SmartMoto , a company which is well known and one of the top brands for electronics in EU . -Side panels are made with the best materials to last long . Not just MATT glassfiber and polyester but woven roving fiberglass and ecological resins . -Navigation tower is made also from a motorcycle spare parts company and not on a small workshop . With top quality materials and hard tested ! We can write many many things more but these are the most importand ,you are not buying a kit which is made from a single person but parts which are designed from serious companies with many many years in the fields ... DOWNLOAD THE MANUAL HERE: 2008-2018 ktm 690 enduro 2008 2018 GEN1 GEN2 Installation Guide 2019-2020 ktm 690 enduro 2019 UP Rally Adv fairing kit Installation Guide
We had the opportunity to work on a BMW G450X and add some parts in order to make it a rally bike ! The parts we used : https://www.perfect-fairings.com/product/mastech-complete-adventure-navi-tower-kit/ https://www.perfect-fairings.com/product/frame-adapter-for-navigation-tower-ktm-690-950se/ https://www.perfect-fairings.com/product/ktm-450-690-front-lower-fender-carbon-fiber-2015/ We also did 2 small side panels to cover the gap between OEM side panels and the KTM windshield . On the Mastech tower we made a special cut to fit the OEM Speedo and also the standard indicators . Customer asked to mount also his F2R roadbook ,so we did it on the tower ,for this installation we used the parts which provided from cuctomer the only we did was few drills in order to mount them :) The challenge was on the way to fit the navigation tower on the bike frame ,on our first convesation with the customer we agreed to weld a tab on front but after few days we change this decision and we made a new bracket .A real bolt on bracket made ,this part made by reshaping our existing KTM 690 Enduro bracket . With few magics the new bracket was ready .This is sure easy to installed as it use 2x upper small brackets and then a M10 U -Bold !! The fender was a direct bolt on job ,no need to do any extra work!! The bike looks amazing ,the overall building takes approx couple of hours as all parts are now made and no need for custom work !!
Dario Pena ,AKA Riding.The.World.DP , its a passionate rider based on Mexico. Dario was one of our very first customers on the KTM 690 Enduro lite fairing kit and the very first one which received the Mastech navi tower! Now after many many rallies which he participated and a lot of Km on adventure riding is the suitable rider to get an accurate feedback after his last 15000Km adventure "Continental 2019" : You can watch a documentary video of his bike build : https://www.youtube.com/watch?v=Lom1Y3uqr8M&t=34s Also dont forget to subscribe on Riding The world DP youtube channel and watch more videos !! https://www.youtube.com/channel/UCQ9VZerijwHlJTp8VFLKNGw
A great build from Austria by Tom.
We received some nice pictures from our friend and customer Rene from Switzerland ,also his feedback : " Hello Dim, hope you and your loved ones are healthy and save. I did wirte a feedback for the the kit you sold me. I will send it via Messenger and hope you will post it. Or i can post it as a comment of the fotos, of my bike, that you postet. To all interrested in the Lite Fairing Kit Gen2, by Perfect Fairings. First, I must say, I’m not a moto mechanic. I do however, have my own bussines in sheet metal production which gives me experience in handling tools. This was for sure helpful but it is not required to install this kit. I had a lot of doubts and questions before I even ordered the Lite Kit. I can not thank Dimitris enough for his patience in answering my emails quickly and always having some good advise. Since this was the first time, for me, to install this kind of kit, I was expecting major problems and therefore I warned my Superhero-mechanic-friend (everybody should have one) well in advance to help me if need be. Turns out my worries did not materialise. Of course there were some minor issues but I filed them under „Beginner‘s mistakes“. After installing the kit, I realised that the bike was much better to handle. Visability is great. Windprotection is great (although I did not look for that). Biggest plus is stability at higher speed! I know, it is an enduro bike, nobody rides really fast on a bike like this. But where I live, I always need to ride on highways to get to the good stuff. All in all, I must say buying the kit was the best decision ever made! Best service from Dimitris! And yes, I would recomend the kit and Perfect Fairings any time. Cheers René"
It was time to start working on the new KTM 690 Enduro,so we start from drawing new designs and ideas about this new kit . The main idea which finally done reality was to keep the standard lines of the bike and make the kit as factory can be ,no new design from scratch but with the same lines . We decide to keep the OEM KTM Windshield from the previous model as we love the design ,its hard hard tested from KTM all these years on the Dakar rallies and all the FIM rallies arround the world .Also it comes with the OEM KTM Stone guard to protect your lights and the OEM KTM headlight mask ! The lights also remain the same Hella street legal lights but with the option if anyone need to update them to Hella LED street legal lights (withg additional cost) ,and also we use the OEM Hella LED position light . Lights comes with a plug and play wiring harness made from top quality materials and following ISO roules ,made from Smart Moto electronics a top brand with high quality standards! Navigation tower is also the same as on the previous models ,made from Mastech . Made from aluminium ,hard tested as we use it now for over 3 years withoout any fault ! With plenty space inside to fix your cables and have access to anything during a trip ,also the cables are inside the tower which provides an extra protection . The main headstock bracket was updated and comes ready and really plug and play ,with a CNC machined bracket and the safety which provide the M10 U-Bolt we use this bracket made to last forever.It mounts easy without removing the ignition key and without relocate the expansion tank. Side panels ... The new side panels are made to make your bike looks that is a factory KTM rally bike and not a kit which installed on your bike .Comes ready to install ,just remove the black side front panels and install your new ones ! Toolbox will be there for your tools as on the OEM panels .Very strong and durable and same time not heavy ! This kit made with love for anyone which like to have a factory adventure bike and not just a kit on his bike ..
This nice bike comes from a very far from us country ... China ! This build took many time in order to be ready as it have some nice and made to order parts ,such as the exhaust lower pipe which is on the right place insteed of the left,this made in order to give the "real" rally look and be as close to the KTM 450 RFR bike . One of the nice things on this bike is the seat as our friend from China didnt change the standard 690 seat but it modified in order to keep the budged low . On this build we provide: Carbon Fiber navigation tower Hella lights with harness Carbon Fiber engine guard protection Fuel tank brackets kit Engine guard brackets kit Also during this build we made some kits for future customers which are doing the same project ,so now we have available : Lower exhaust pipes Complete set of brackets Wiring harness for fuel pump ,Keihin pump Wiring harness for lights Hella lighs , H3 , Street legal Hella lights LED ,Street legal Lower fenders Radiator protection Rally style Fuel hoses kits ,with one way valves and fast connection couplings Carbon Fiber engine guard ,toolbox and brackets Navigation towers ,Aluminium or Carbon fiber If you looking any of the above parts feel free to contact us !!
Julien from Switzerland recently shared some pictures of his bike which is equipped with our 'KTM 9X0 Rally parts' . The colors are inspired from MotoRex Front lower fender is made higher than the stock fender ,more fun for offroad use Navigation Tower is made of High quality Carbon Fiber Rear panels and fender are also made by us Lights are street legal ,Hella . No modifications required to fit the kit on your bike Enjoy: