DRZ Rally Kit Design and Build! | Part 5 | On Two Wheels

[@Polmilbirt]

It's a blessing I came across your vid, almost flipped youtube upside down just to get a vid about DIY conversions of motorcycles into adventure, rally or dakar headlights. Learned alot from your vids, I'm looking into buying a Honda crf 150L and turning it into a mini crf 250 rally or a yamaha wr155 into a tenere 700, I'm planning to use 3d printing for the casing to give me cleaner look. Great content, looking forward for your upcoming vids.

[@OnTwoWheels]

Glad you liked it! 3D printing is next level!! that ought to look amazing I reckon!

[@TrekMoto]

Well done! Might I suggest making the tower such that the consumer can choose their own headlight (within certain constraints). For instance, I like Baja Designs lights, but they are more expensive than most and not appropriate for everyone. If your tower could accommodate their Squadron Pro lights you'd have a winner!

[@veetwotls]

Would not be hard to do & they could offer it as an 1 or 2 baja design Squadron sport/pro light upgrade option in there sale inventory

[@OnTwoWheels]

Thanks for that mate! One design principle we are trying to stick to, so it make the kit customizable, because tastes vary and we all want a tower 'just the way we like it' . We ARE planning on having different light setups, though we've not made a final decision on yet. My mate Davin is the "light connoisseur", so I'll ask him about the Squadron Pros.

[@OnTwoWheels]

@@veetwotls Looks like everyone has a sweet tooth for nice lights! So we'll def start looking deeper into that!

[@michelt4390]

Agree on the nicer-lights. Veettwo Racing. What kind on of $$ are we talking about for a kit? I'd be curious to see that on a WR250R

[@Just_a_Plane_motorcycle_rider]

Looking forward to seeing "Version 2" with the contoured Screen, now do one for a 2015 500EXC and I'll sell a kidney to buy it :O)

[@OnTwoWheels]

The reason we want to do this is because we don't want people having to sell kidneys to treat themselves to something nice this Christmas! haha! And Yes! The KTM frame IS something we're considering. We'll keep it in mind mate!

[@gumbysenduro6546]

Well done we need ppl like you to help get the ball rolling with fabrication in this country, the tower looks great and suits the Drz nicely, looking forward to seeing your version2 if this is the standard :)

[@OnTwoWheels]

Thanks mate 👍 Having gone through this process, we too have a new found appreciation for the R&D that goes into a product!

[@jvanschie942]

Realy nice job .I will make one for my hp2 enduro ,very well done thanks all the best with your venture

[@IKpole]

Oh man, it is really nice of you to put it in here. I think it should be useful for drz adventure riders. God job)))

[@OnTwoWheels]

Thanks for the encouraging words mate!! I've done a ride last weekend! you'll see the video soon! 😃

[@saspeedwayrider]

Looks awesome mate im definitely keen for one mate. Im building up a drz 250 rally/adventure bike and would love one of these for sure👌

[@OnTwoWheels]

You're in! The DRZ250 and the DR650 are definitely in our list! I'll touch base with you when we've got the process going mate! If you have any other questions, just drop me a message/comment :)

[@saspeedwayrider]

@@OnTwoWheels sounds good to me mate. Cant wait 👌

[@saspeedwayrider]

@@OnTwoWheels how can i get in touch with you mate?

[@AjieCo]

thanks for the knowledge...very inspiring...want to ask can you see how to connect it to the motor body? Thank You

[@djdehne]

I know this video is a couple of years old, but I would be interested to see how this project is progressing. And if possible buy a rally tower kit for my DRZ.

[@Revmarine0351]

Need perforated vinyl on the take mate. Great vid!

[@OnTwoWheels]

Right now I do have some 2cm perforations/slits cut at every 2cm, but it's not proving to be enough, I think I might need to get a vinyl with proper holes cut in it. it's a WIP for sure :)

[@OlmanEg]

Your tank rap needs to be perforated. Try using a leather rolling perforator to put small holes in the rap. Never another bubble!

[@OnTwoWheels]

I've actually cut 2cm perforations at 2cm gaps, and occasionally I run a squeegee to squeeze out air bubbles; but it's not permanent. I think the perforations need to be proper holes, and the vinyl needs to be the high tac vinyl for it to work on a fuel tank.

[@jamieslalom]

Great video. Well done for having a crack at your own tower! I’m definitely interested in buying one.

[@OnTwoWheels]

thanks for the encouragement mate! When we have everything prim and proper with the tower, we'll let you know! Cheers!

[@Offracebrasil]

Awesome project!!

[@nedmacallen]

Man you really did a good job on this, thanks for editing and sharing! Will you be selling kits? Or sharing design info?

[@OnTwoWheels]

Yes, We are planning on selling the kit. But we want to bring it to a quality standard that's comparable to other commercial kits. So there's a lot of R&D and redesign we're putting into this (beyond what's in this video). Our target is to get this under people's Christmas tree this year!

[@seaneaston3062]

Very well done! You boys are clever. I am a huge DRZ fan. In fact I raced the Sonora Rally in Mexico this year on my DRZ. I ordered a rally kit from Perfect Fairings in Greece which looked cool but the aluminum tower cracked during the race. I was considering the highway dirt bikes tower kit when I came across your videos. Again, beautiful work. How can we get in touch? I'm interested in what your kit costs. Is it competitive with HDB? There are also similar designs from motominded and RMS

[@OnTwoWheels]

We've been riding with the tower and putting it through some real torture testing to make sure it hold! The pricing depends on what options and specs you want to go with; and w are looking to expand the model range as well as the bikes this will fit on! You can reach out through our FB page facebook.com/AdventureRallyX

[@ShaneRajasinghe]

Looks mint man!

[@OnTwoWheels]

Thanks thanks!

[@gc1862de]

Fantastic job, im interested in one

[@OnTwoWheels]

I'll keep you posted mate!

[@rckr951]

Great job!!

[@OnTwoWheels]

Thank you!

[@Thumpermad]

Really enjoyed watching your Rally Tower build man so many considerations and doesn't look too bad in my opinion. That bikes looking huge when you stand beside it especially with the tower installed. I was checking out the Nomad Rally Tower for my KTM790R @ $2K au plus delivery I didn't want to spend but I did like the design it's very similar to yours I especially liked the headlight set-up and the connections plug and play with the CAN bus module which I'm not familiar with, it's another KTM fail safe device I think and I'm also not sure about ADRs with swapping out headlights with LED spotlights I guess if you zap a Policeman at night you'll soon find out if the lights are compliant with ADRs or not hahahaha top video thanks for sharing huge respect Happy Trails

[@OnTwoWheels]

Thanks mate! As for the headlight, yes this 2 LED set-up isn't ADR compliant. But the next version of the tower (which I currently have only the bike) uses a already ADR approved headlight. So no trouble with the popo. :)

[@NamilaRadith]

Fantastic build! Is this DRZ 400E ?

[@OnTwoWheels]

Thanks! Yep, it's a 2009 E model.

[@veetwotls]

Looks a Good cheapish Adventure setup option :thumbs up well done , compared some dedicated rally kits out there that high priced for average person. Lighting cant pass Baja Designs there the best lighting i learned many years ago you get what you pay for with lighting. You could offer it as an 1 or 2 baja design Squadron sport/pro light upgrade option in your sale inventory. I'd add a relay (how i run all my bikes) so both lights are on when switch to high beam (it allow for spread & distant view for wildlife ahead & coming in from sides of your riding path) . Screen bolt holes i'd put rubber grommets in them. Acerbis tanks are designed to breath through the plastic won't stop it bubbling using wraps , paint etc (only acerbis tank designed to paint is the KTM450RR Tanks which are also used on the Husquvarna 701RR) .

[@OnTwoWheels]

We'll certainly consider the Baja designs light! Interesting that you mention getting both lights with high beam; Davin has that setup on his! I was also wondering if rubber grommets were needed, but so far it's been good. It's sitting pretty firm, and the poly carb does allow flex if necessary. But yes, once lockdown ends we want to take the bikes out for bit of a shakedown. As for the tank, haha well, the eternal optimist in me is hoping i get a solution for it :D

[@drzrider3440]

Also for vynal wrap. Get a small.hooe punch. Punch small.like 1/16 inch holes all over it. I have decals that went all over the tank. Came with tiny holes in it. Never once did it bubble up. And you can use spray paint on anything. Just use 2K 2 part spray clear over it. I did a helmet, dropped it, and the paint dented instead of chipping. The paint has a hardener in it. The draw back is once you puncture the hardener, you have to use the whole can.

[@OnTwoWheels]

tried that. in fact I cut 20mm slits to let air bubbles out. It's still not enough. What I need is high-tac vinyl that doesn't come off easily. I ended up polishing the tank and using some smaller decals on it in the end :)

[@drzrider3440]

@@OnTwoWheels yoyr slits are two far away from each other. Holes work and they work great. Never once a bubble. Had my decals on for 4 yrs before doing more custom work. Small holes, not slits. And not pin holes. Actual round open holes 1/16 to 1/8th inch in size. About 1 inch away from each other. All the bikes I install these on, which is a lot of them, enough to loose count, i have never once had a bubble issue.

[@OnTwoWheels]

@@drzrider3440 Was this on the stock Suzuki tank or a Safari tank?

[@drzrider3440]

@@OnTwoWheels 4 gallon IMS plastic tank.

[@EricBanner571]

Looks really good, well done. Could you advise what the total weight is including the screen, tower, hardware and lights?

[@OnTwoWheels]

So all the current component add up to little under 4.0kg, but we want to use a lighter polycarbonate in the next version. And funny enough some of the heaviest parts were the bolts. So with the new design we use fewer bolts. So in the end we're probably looking at something just north of 3.0kg. But also interesting is that the stock headlight, headlight cover and the 2 metal fork brackets that we remove weigh 1.6kg. So you'll be adding less than 2.0kg, and that too onto the frame and not the handle. I don't know if it's a placebo effect, but i feel like the bike handles better now!

[@Bongo_Fury]

Maybe you could try something like a derma roller to perforate the tank vinyl. It would put thousands of tiny holes so hopefully it will breathe.

[@OnTwoWheels]

I did try that! Pinholes just aren't big enough. And I've come to realize that unless its a high-tac vinyl, and has big enough holes which are close enough, the bubbles are unavoidable. More so on the safari tank than even the stock tank.

[@Bongo_Fury]

@@OnTwoWheels bummer.

[@Matteus89]

Nice fairing. Could you send over (maybe pisc) all the measures of your fairing (inkl lamps measures) Realy good job. Keep me updated- Im interested in one :))

[@OnTwoWheels]

Like most design projects it's ongoing! Davin's just testing out the latest modifications before we go into mass-production. Stay tuned to see how the end product comes out!

[@drzrider3440]

Also just came across your channel. Totally awesome. Huge DRZ guy...as you can tell by my handle. I fix DRZ's for new riders. Like the current one i have working on is an '03 E model. Rebuilt his brake calipers fixed his water in oil situation and added some lighting. Have built 5 of these. S SM and E. I know what im doing when it comes to these. So yeah, I have tried many different patterns for a rally fairing. Couod dingure out how to mount it up...i believe you have the base mount mounted to rsdiators. Great idea. Please let me know. Im looking for your main mounts that mount to frame and the big Suzuki piece. Thats all I need. Then ill cut and customize the rest.

[@OnTwoWheels]

The current tower has been a test bed (even though i have been riding with it fine) which we have been trying to refine in design. We'll do an in depth review of the new design soon! :)

[@drzrider3440]

@@OnTwoWheels awesome. Keep me updated. I plan on using the fairing from a Honda X-ADV 750. Take a look at it. Fits very nicely in front. I also have two squadron pro series lights I will be using as head lights. The fairing is nice, has a good curve to it and the top is in a shape that will allow for cut to fit by trimming it down if needed. I would perfer to use a solid mounted rally style set up vs the current set up that attaches to handle bars. Im sure I can manufacture brackets that will work fine, but if I had your frame mounted brackets and the ones with the Suzuki cut outs, I can then finish this up nicely. So if you end up getting another set of just those brackets, id purchase them from you and make the other parts I need myself. Keep ne informed. Im a huge DRZ fan. Put over 40,000 on my 2011 so far.

[@alessioliotta8030]

Your project is fantastic ! Can you share the measures of the various parts ,so I can do it again . Thanks 👍

[@OnTwoWheels]

Cheers mate. You can check out the end product in the store in the link in the description

[@kai.v3370]

Can you show us the bracket wich is connected to the Frame or tell me how it works? Its a very nice project and i want to build my own.

[@OnTwoWheels]

Thanks mate!! you can reach me on ontwowheelsau-at-gmail.com

[@Mrmizilplix]

looks good

[@OnTwoWheels]

Thanks mate!

[@lancepoteet2172]

Take my money! I saw the “by Christmas this year” comment, but what ballpark number are you looking at? That’s what kills me with any rally kit, folks tend to be awful proud. Super cool design though!

[@OnTwoWheels]

I've added the link to the website in the description. There's a few options based on what model you want..

[@lancepoteet2172]

Slick man, congratulations. Still other fairings I’ve found in the 1k to 2k price range for us, glad to see you’re on the bottom end of that. But geeze that’s a lot of money for an 05 drz400 that’s hardly worth that much itself in the states. I’m sure you got prices as low as possible/made sense, shit just cost too much these days! Never the less, my name will be on an order form within the next year..

[@marianobruschi6274]

Hola! como sujetaste la torre al chasis?

[@jed8five897]

There is a pretty big thread on Adv Rider forum on this topic called diy rally tower

[@OnTwoWheels]

Yeah, that's been quite inspiring!! End of the day, the internet indeed has a wealth of knowledge!

[@alexcouto1818]

Im keen dude. DrZ400E also

[@OnTwoWheels]

Great mate! We're ironing out some design factors, and hope to have it ready before Christmas mate! Keep an eye on the channel so that you get to know when it's in the market!

[@alexcouto1818]

@@OnTwoWheels got a ball park figfure for price?

[@OnTwoWheels]

@@alexcouto1818 We're getting there. It won't be one fixed price though. The pricing will change based on the combination of customizations, so you can pick and choose the options you want :)

[@GR31M4NN]

Hi bro. May I please see a clear photo image of how the very first pair attaches onto the frame of the motorcycle. I am dying with curiosity since in the intro you said "no drilling, no welding" ...

[@OnTwoWheels]

So it's actually clamped onto the bike frame. I'll be doing another video on the new version of the tower soon mate :)

[@GR31M4NN]

@@OnTwoWheels I eagerly await that, sir

[@coloradoraptorguy9250]

Are these currently available?

[@MikeBarnacIe]

Interested in this for my drz400. I am interested in seeing how you attached the tower to the bike though. Also, the screen and lights off centre at 15.28 or is it just the angle, I recall seeing some one had issues on another rally screen kit build with issues like that but may be a different bike I can’t be sure

[@OnTwoWheels]

Actually the tower is straight and aligned with the frame. It's the handle/fender that's slightly turned, hence the asymmetry. And the tower is mounted with a bracket (rather than a weld) so that if/when the day comes, you can always put the bike back to standard.

[@MikeBarnacIe]

@@OnTwoWheels thanks for the reply. Please keep me updated with any products going on sale

[@OnTwoWheels]

@@MikeBarnacIe certainly mate! Will do!

[@UnleadedApe]

Great job, would be interested to hear pricing (shipped to UK!) :)

[@OnTwoWheels]

We're in the market mate! You can check out the towers in the link in the description. And we're looking at expanding the product range as we go!

[@UnleadedApe]

@@OnTwoWheels ah that’s fantastic! Congratulations! Looks very reasonably priced as well! Will take a look as soon adventures are allowed and I’m back in work 👍🏽

[@muzzarobbo]

Did you look into building a kit around the factory ktm rally screens like some other kits do? What is the price of that screen on its own if you did? cheers

[@OnTwoWheels]

We thought of the KTM design, but didn't go down that path. The thing is it would require using the KTM headlight. (The KTM screen has a big cutout for the headlight and that would limit us to using the expensive KTM light or designing a light assembly to fit that shape.

[@evantaylor9790]

I was curious how thick the polycarbonate windscreen is and roughly how tall from top to bottom?

[@OnTwoWheels]

It's 3mm thick and about 35cm tall

[@kurtkeltner9140]

Estimated price and build time?

[@drzrider3440]

So how much for the mounting hardware? Very interested. I have a fairing already, just would like to have all your hardware to mount it to. If you can sell me that, id would be very interested.

[@OnTwoWheels]

I'll be posting an update on pricing options (based on your customization) once we have the design ready and the parts quotes in! Stay tuned!!

[@GSchrijver]

can you tell me what a tower would cost? DRZ400 Sm, i would be interestred if the price is right. how long would it take to deliver to france?

[@OnTwoWheels]

Hey Gerard, There's 2 models. You can check them out here. :) adventure-rally-x.myshopify.com/

[@GSchrijver]

@@OnTwoWheels $1000 is a pretty price for a few pieces of aluminium

[@dav1n46]

@@GSchrijver that's $1000 Australian. Roughly $600 Euro. But that comes with a screen, powder coating, wiring loom and switches and lights

[@marcomoto-mecanicasergio6485]

I want built a nav Tower for my XT600e. Your vídeo help me with ideias about How to built. Sorry my bad English.

[@OnTwoWheels]

I'm glad it helped you mate! Not sure if the design would fit yours perfectly, but hopefully it helped you think of some the considerations when building a tower no matter what bike :)

[@Alejandrohenao2003]

Man I'm really interested in you tower, how can I get one? Any advice to buil my own?

[@OnTwoWheels]

stay tuned to the channel mate! You most certainly can build it yourself. But something we also realized on through the process is the amount of R&D and trial-and-error that goes into the process. Plus we do want to produce(sell) these in in greater volume, so we achieve decent volumes of scale. S We're finalizing the design and the 'customizable' parts for each rider, so you'll be able to get one that suits your exact need. So stay tuned!

[@dexterax6634]

What's the thickness of the polycarbonate sheet

[@OnTwoWheels]

2mm

[@TheHolfeldian]

You guys selling designs for this?

[@billlougheed1227]

So when are you going to be selling your rally tower?

[@OnTwoWheels]

It's already out mate. Check out adventurerallyx.com

[@geekcody]

Interested in a rally kit

[@OnTwoWheels]

Cheers mate, the link's in the description :)

[@slakk5093]

Interested!

[@OnTwoWheels]

Appreciate your interest mate :) keep an eye out for progress, and I'll reach out to you too when it's ready!

[@imthimerchandiser243]

hi i m a new subscriber. i would like to enquire about the rally kit for my KTM390. kindly revert please

[@OnTwoWheels]

Thanks for the support mate!! the 390 is fairly new, so there's no model ready yet.. but follow the ARX page and you'll be able to get one when it is available!

[@ramazankeskin6448]

Hi crf 250 L rally kit??

[@OnTwoWheels]

Possibly in the future mate! keep an eye out on the page! The 250L comes with a Rally version though right?

[@Mrmizilplix]

how much is it going to cost?

[@OnTwoWheels]

I've added a link to the shop in the description. You can check out the options :)

[@mcurranb]

I NEED A RALLY TOWER... I have a drz400. this is awsome. I am in..... send me details

[@OnTwoWheels]

We're launching the tower in a matter of days!!! I'm so excited too! Make sure you subscribe and stay tuned mate :)!!!

[@mcurranb]

Shipping to the USA?

[@OnTwoWheels]

@@mcurranb more than happy to mate :)

[@patpaylado8338]

I want one please🥺😁

[@OnTwoWheels]

You can! Check it out here mate :) adventure-rally-x.myshopify.com/

[@ototem]

Are you shipping Europe?

[@OnTwoWheels]

Yes we do; you can check out the online store (link in description)

[@PsyhcoTR]

wretched

[@OnTwoWheels]

Thanks mate! Stay tuned for the new version which will be coming out in a matter of days!!!