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Dan Mickan’s KTM 500 EXC “Vinduro”…
For greater than a decade, the KTM 500 EXC has reigned as one of many final street-legal dust bikes ever produced. Till the bike Kato hit the market, dust riders who wanted to tie collectively trails, dust roads, and pavement have been usually compelled to accept chubby, street-oriented dual-sports, or else try to get their dust bikes plated and insured.
KTM modified the sport with the five hundred EXC, combining the chassis and suspension of the race-winning XC-W enduro collection with simply sufficient road requirements to make it authorized — a contemporary dual-sporter’s dream:
“It’s fairly presumably the best dual-sport bike in historical past. It’s an unbelievable dust bike that simply occurs to have a license plate, flip alerts, a horn…” –Filth Rider
Enter our new buddy Dan Mickan of Brisbane, Australia, who was thinking about selecting up an previous Honda XR600R for Mud Hustle and different vinduro occasions in his space, when his eye turned to the bone-stock 2015 KTM 500 EXC Six Days version sitting in his storage.
Dan reckoned he would spend a load of time and cash upgrading and modernizing an older XR…or he might flip again the clock on the KTM he already had.
“I used to be actually blown away by the RSD “Kurt Caselli” construct, which mainly launched me to the concept that you would customise a dust bike which, till then, I by no means even thought-about as a chance for a customized construct. So, with that in thoughts, my plan was to construct a Nineteen Eighties styled classic enduro machine utilizing my KTM 500 as a base to scratch that itch of an classic XR650R dirtbike.”
It’s what we typically name a “retromod” — a contemporary bike modified to resemble one in all its classic ancestors whereas retaining its modern-day efficiency. (Versus a restomod, a classic bike that’s modernized on the efficiency entrance, however maintains a lot of its unique design and silhouette.)
Dan wished to create a machine that might look proper at dwelling at a vinduro occasion, however with out sacrificing the KTM’s useful prowess:
“I wished the bike to be able to driving full-on enduro because the KTM was initially designed for, so it needed to be sensible and the design wanted to look good however not detract from the flexibility of the bike to be thrown round within the bush. So as an alternative of shopping for an previous XR, I began on the construct.”
A $15 Honda XL185 tank served a hub of the construct, and Dan, who has three younger youngsters at dwelling and a demanding job as a development venture supervisor, labored with an array of native fabricators and contractors to hold out his designs, leaning on his venture administration expertise. Assist got here from buddies like John Bancroft Arnott (a “complete legend”), the crew at Skinny’s Storage (Brisbane’s group storage), and the Brisbane moto group as a complete.
“Alongside the way in which I reached out to a bunch of individuals to bounce concepts off and run design recommendation by and the native Brisbane bike group is de facto filled with nice folks. The ultimate product wouldn’t have turned out as nicely with out the enter from these folks, all of them know who they’re.”
Under, Dan offers us the total rundown of the modifications and design, and we’ve obtained extra glamour pictures from the proficient Gabe Veit, in addition to pictures from the KTM’s outing at Mud Hustle, courtesy of Mint Rig Studios and Picture Gusto!
KTM 500 Retromod: Builder Interview
• Please inform us a bit about your self, your historical past with bikes, and your workshop.
I’m positioned in Brisbane, Australia. I work as a development venture supervisor and bikes are a passion/obsession for me, they’ve been since I might journey at age 10. I’ve all the time been captivated customized bike (café racers / scramblers) that got here out of locations like Deus and Ellaspede in Brisbane and have all the time wished to construct one thing distinctive.
I do know my means round a workshop however I’m not a very proficient fabricator, plus I don’t have a workshop to manufacture in, so I needed to mainly design and venture handle the construct as an alternative of doing all the work myself. This suited me due to the talents I’ve from my everyday work. Additionally I’ve three younger youngsters and so discovering the time to spend constructing bikes is all the time a problem. Hopefully after I get extra time as the youngsters develop up I can do extra fab work myself.
• What’s the make, mannequin, and yr of the donor bike?
2015 KTM EXC500 Six Days version.
• Why was this bike constructed?
Someday in 2018, I used to be trying to purchase and previous Honda XR600R as a result of I wished a classic motocross / enduro kind bike to journey at occasions like Ellaspede Mud Hustle or some native vinduro occasions. Nonetheless, on the similar time I additionally had a 2015 KTM 500 Six Days version sitting in my storage. I assumed that if I purchased an previous XR then all I’d do is journey it, throw cash at it to enhance suspension and engine efficiency and I’d by no means journey my KTM 500.
I used to be actually blown away by the RSD “Kurt Caselli” construct, which mainly launched me to the concept that you would customise a dust bike which, till then, I by no means even thought-about as a chance for a customized construct. So, with that in thoughts, my plan was to construct a Nineteen Eighties styled classic enduro machine utilizing my KTM 500 as a base to scratch that itch of an classic XR650R dirtbike.
In doing this I’d have a motorbike that might have the retro classic enduro seems however have all the trendy engine efficiency, reliability and suspension tech. I wished the bike to be able to driving full-on enduro because the KTM was initially designed for, so it needed to be sensible and the design wanted to look good however not detract from the flexibility of the bike to be thrown round within the bush. So as an alternative of shopping for an previous XR, I began on the construct.
• What was the design idea and what influenced the construct?
RSD Kurt Casselli construct was an inspiration, earlier than that I by no means heard of anybody constructing customized dust bikes. I did all of the design work by printing out scaled pictures and sticky-taping completely different components collectively till I preferred what I noticed (see photograph).
• What customized work was finished to the bike?
I began in December 2018, stripping the bike again to border and wheels and engine. I can weld however I’m not an excellent welder in any respect, so to ensure the construct was high quality, I needed to outsource the fabrication work whereas offering clear directions.
For the subframe, I constructed a mock-up out {of electrical} conduit and gave that and a set of detailed dimensioned drawings to my fabricator who then made a precise reproduction in chromoly metal. With a little bit of forwards and backwards I obtained the scale and proportion that I used to be in search of, and the fitment on the bike was spot on. I made an intentional effort to design the bike in order that the ergonomics of the unique 500 weren’t misplaced as a result of I totally intend on driving this bike because it was supposed to be ridden.
The tank might be the design factor that the entire construct revolved round probably the most. It’s off an early 80s Honda XL 185 and I adore it for its boxy strains and small measurement (7 litres after modification). Once more, I despatched it off to a neighborhood fabricator to have it modified to suit the bike and new subframe. A giant problem was getting the gasoline pump to suit into such a small tank, however with so much if effort my fabricator made it work.
Add in a seat pan to swimsuit as soon as the tank was mounted, and I went on to get the massive blocky blue seat made. It needed to be blue to match the early 80s KTM MX machines. From this I made a decision the tank needed to be white additionally.
I sourced an ordinary Danmoto exhaust as a result of it was finest 80s fashion pipe I might discover and had the inventory headers modified to match the strains of the brand new subframe.
Subsequent was so as to add on the Acerbis Commonplace plastics that are actually acceptable to the period and likewise very sensible. Within the occasion I throw the bike down the aspect of the hill whereas out on the paths, I can exchange them if wanted.
I used a inventory KTM 500 airbox and had it modified to suit throughout the new subframe in order that I might use the inventory air filters and battery field. This additionally helped to connect the inventory rear mud guard to. There are a couple of extra locations that mud and dirt can get into the airbox so I put in a “finke spec” funnelweb filters that’s a bit thicker than regular. The fabricator then did some ending touches to the aspect covers and fitments and it was prepared for paint.
By this level it was time to begin enthusiastic about the ultimate colors and graphics. I had a bunch of concepts, and whereas I wished it to have that 80s vibe, I additionally wished to maintain a nod to the 2015 Worldwide Six Days Enduro that the bike initially was constructed to rejoice. This explains the sunshine blues and Argentina particulars.
Working intently forwards and backwards with a graphic designer I ended up on the closing design. The brilliant white, darkish blue, orange and lightweight blue are a superb mixture, however I needed to be aware to not overuse the graphics as a result of the bikes of the time had very minimal decals.
The method was sluggish and the construct took me about 3.5 years due to time and value restrictions. I didn’t have the cash to take my bike and the thought to a customized bike store and simply pay for the construct so I had to determine probably the most value efficient answer with out sacrificing high quality. As a result of I used to be on a funds, but in addition wished to get high quality work finished after I might so that every one took time. Within the time value high quality triangle, I needed to sacrifice time to get high quality at an inexpensive value.
Alongside the way in which I reached out to a bunch of individuals to bounce concepts off and run design recommendation by and the native Brisbane bike group is de facto filled with nice folks. The ultimate product wouldn’t have turned out as nicely with out the enter from these folks, all of them know who they’re.
• Does the bike have a nickname?
Nope, I simply name it my KTM Vinduro.
• Any concept of horsepower, weight, and/or efficiency numbers?
I feel the inventory 500 places out near 60bhp on the crank and weighs about 105kg? I don’t suppose any of my modifications have lessened the burden, the truth is, the metal tank most likely added to the dry weight by a couple of grams, not that you may discover.
• Are you able to inform us what it’s wish to journey this bike?
It feels similar to driving the usual 500, wheelies in any gear and has heaps of torque. Once I did its first shakedown journey at Mud Hustle, I had forgotten how a lot I liked driving this bike.
• Was there something finished throughout this construct that you’re notably pleased with?
I actually like the way in which the seat and tank got here collectively, that for me is the perfect a part of the construct. The construct mainly revolved round this previous $15 honda XL185 tank. Love the sq. strains and the seat needed to be sq. too. Additionally I’ve by no means been a fan of the brilliant orange of KTM — I simply purchase them as a result of they’re nice bikes — however I really like the old fashioned blue and white scheme with a spotlight of orange.
• Is there anybody you’d wish to thank?
I subbed out quite a lot of the work and don’t really want to record everybody that touched the bike (there have been a couple of duds alongside the way in which), however post-covid and after a couple of years, the venture had kind of stalled and so I reached out to a mate, John Bancroft-Arnott, and requested if he might assist me get it completed at Skinny’s Storage in Brisbane. He helped with the ending touches and particulars and likewise some useful gadgets (like blocked injectors from sitting for therefore lengthy and a stuffed gasoline pump). Whole legend and it received’t have turned out to be the bike it’s with out his assist in the ultimate days.
Mud Hustle!
Observe the Builder
Builder, Dan Micken: @danmotomoto
Skinny’s Storage in Brisbane: @skinnysgarage
Buddy, John Bancroft Arnott: @forwantofabetterusername
Images: Gabe Veit (@gabrielveitphotography)
Images: Mint Rig Studios (@mint.rig.studios)
Images: Picture Gusto (@photogusto_au)
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