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Brain Eraser: A KTM RC8 with CNC Everything

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Brain Eraser: A KTM RC8 with CNC Everything Brain Eraser: A KTM RC8 with CNC Everything

Brain Eraser: A KTM RC8 with CNC Everything

A lot goes down at EICMA every year. For father and son Dino and Marios Nikolaidis, it’s a chance to represent their booming family business, DNA Filters. Then last year, they noticed the growing modern custom scene, and decided to build a bike themselves.
They don?t do things by halves. Dino’s a mechanical engineer, Marios is a motorsport engineer, and both are well versed in CAD/CAM design. And the DNA factory is loaded with everything you need to build a killer custom?including state-of-the-art CNC machines.

It took Dino and Marios two weeks to nail down the design of this KTM RC8. ?We wanted to mimic the style of the 70s and 80s,? explains Dino. ?DCR-017 was to be just a frame, engine and wheels, with an analogue clock?no plastic covers and no carbon fiber.?
?We wanted a 2017-spec superbike beast. But undercover?a sleeper.?

Since DNA is in the business of making filters, it made sense to make a filter the focal point of the build?just like on an old American muscle car. Back in 2012, DNA won a coveted Red Dot Design Award for an airbox replacement kit for the KTM 990 Super Duke, so that’s the setup they picked.
The air filter was designed for the KTM LC8 990 V-twin, but the guys wanted more torque and power. So they chose the LC8 1190, as used in the KTM RC8 Superbike. And the standard version of the RC8 was not enough, so they went for the R version.

?We needed a tubular trellis frame and when we saw the RC8 naked we were blown away by the minimal, beautiful steel frame,? says Dino. ?That was a jackpot?just what we needed.? A suitable donor was torn down, and the design began in CAD. Dino tackled the front, focusing on the tank, air filter, clocks and oil cooler, while Marios handled the back, including the seat, under-seat section and subframe.

It took two months of designing, arguing and fighting. But the result was worth it.
From the beginning, the guys knew they wanted to CNC-machine as many parts as possible?especially larger items like the tank and seat. It was partly because they had all the tools to do this in-house, but also because they genuinely like the visual effect of the tool paths that a CNC mill leaves behind. So nothing has been painted, polished or ground down?just clear coated to protect against oxidation.

The three biggest parts?the tank, seat, and under-seat section?were each machined from a solid block of 5083 H112 grade aluminum. It’s a special alloy that is annealed and stress relieved, so it can be machined down to as little as 2mm thick, with minimal distortion. The tank’s block alone weighed in at 146 kg, with the other two coming in at 60 kg and 24 kg.
Making the tank from a single block proved to be almost impossible. It was stressful too, since Dino and Marios only had one (expensive) block to work with. First, they milled out the inside of the tank from the bottom. Then they flipped it over, set it in a special jig and did the outside.

A bottom plate and fuel pump ...
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Brain Eraser: A KTM RC8 with CNC Everything Brain Eraser: A KTM RC8 with CNC Everything


Fuente de la noticia: bikeexif
Fecha de publicación: 07-11-2017 21:50
visto: 0

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