KTM 525 Hybrid

[jread14]

Well I started this project about a year and a half ago, and I am just now getting a chance to start putting it together. I want to make sure it all works well together before everything is off to the powder coater.

[jread14]

another

[jread14]

custom intake.

[jread14]

another of the intake

[Nahum]

What kind of material did you use for this custom intake and how did you manage to make a mold for this!? What kind of material was the mold?

Everything seems to fit very well!

[c450Razy]

looks to be fiberglass;)

[jread14]

Stirafoam was used to build the mold and then it was wrapped in fiberglass.

[matt250r21]

How wide is your T-pin a arms?

[Derrick Adams]

Very nice job on the intake tube. Curious how you got all the styrofoam back out when it was finished?

[250Renvy]

You wouldn't happen to have any pictures without the motor in the frame would you?

I'm going to be starting a hybrid and am still planning on the design. I'd like to see how the ktm mounts in there, unless you know where to find KTM microfisches?

[Nahum]

https://www.ktm-parts.com/mm5/merchant.mvc?Screen=OEMFINDER&Store_Code=K

[Quadforce]

Originally posted by Derrick Adams
Very nice job on the intake tube. Curious how you got all the styrofoam back out when it was finished?
My father actually built the intake tube and did all the metal fab work. he used styrofoam to form it then he wrapped it with fiberglass an epoxy and inlaind some carbon fiber that he had laying around for extra strength.. that is the grey lines you see in it. turned out very nice. He actually offset the motor to give a better center weight for the bike. that involved much work because he had to machine the swingarm to acommidate. Overall the project came out very nice.. took a long time as my father is disabled but I think it was worth the wait. I hope that you enjoy it when y ou get it back together Jason.

[Quadforce]

here are some photos that my father took while working on this project... even has pictures of the mold that he made for the intake. Couple pictures are of a custome made skidplate that attches to the lower frame to protect the motor.. he centered the motor and lowered it in the frame to keep more of the 250R geometry. also custom made center section of the pipe to clear everything.
http://s272.photobucket.com/albums/jj178/quadforce_photo/ktm525/?start=0

[jrspawn]

Did you guys cut the rear vertical frame rails and reweld them up?

[Quadforce]

when he bought the frame it had been trashed.. they were rewelded and the scabbed over with extra tubing for additional strength.

[jread14]

Spawn,

This one is going to take a ton of tlc and fine grinding to get it in your realm of perfection, but I am hoping to get time to start working on it in the next couple of weeks and give it a shot. I have some brakets that need to be moved and some added so hopefully I can get this done and then I should have the time to work on it. My sons MX season is just around the corner, so I had better get started or I will never get it done... :ermm:

[jread14]

J,

Thanks for posting the pics...

[Quadforce]

you are welcom

[Quadforce]

any new pictures Jason

[jread14]

Originally posted by Quadforce
any new pictures Jason

No pictures... I have not gotten as far as I had hoped to... It is all together and rolling... I am in the process of welding tabs on it for the battery box. After that, it is just getting the electronics ran.

[jcs003]

the intake tube is trick. you guys do nice work.