Luxon 150SX - Weight, First Ride

Luxon MX
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11/22/2018 1:08pm
The sprockets above are using a PVD type coating similar to Titanium Nitride, but Zirconium Nitride instead. That would be really expensive, plus it would look pretty ugly unless I polished the chassis (and then it would look pretty cool). But that's way more work than I'm willing to put into it!

I've got some Cerakote supplies coming and am going to attempt to do that myself. It doesn't look all that difficult; the work is mostly all in the prep plus the C series Cerakote doesn't require an oven to cure. More than likely going with the Titanium color:

https://www.cerakoteguncoatings.com/finishes/C-105Q/titanium/

Here's the chassis now after blasting. Still need to rough up a couple of spots, blow it all off to get rid of the blasting media, and prep with acetone.


2
navalseabee
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11/22/2018 1:21pm
Ti would be a nice neutral that any plastic/graphic could go with and still be unique.
Luxon MX
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11/27/2018 5:09pm
Cerakote should be here this week and the swingarm just came back from anodize. This is hard anodize, so it should hold up pretty well. The bearing bores and linkage mount were masked to prevent anodize buildup which would put their tolerances out of spec. It will be nice to start putting things back together!


9
navalseabee
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11/27/2018 5:11pm
?

The Shop

Luxon MX
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11/30/2018 11:43am
Cerakote showed up yesterday. Got a few different colors so we can do the chassis, engine, calipers, and various other bits:



I've never sprayed Cerakote before, so why not start with the most difficult part of all? Putting the forklift to good use:





And once all the spraying was done I moved it into the office. This is the C-series Cerakote, so it is air cure. In a day you're supposed to be able to handle it and install parts, but full cure is in 5 days.



Overall it came out pretty good. A couple runs, but nothing terrible and mostly in non-visible areas. I was mostly concerned with getting good coverage over all areas so things don't rust, which forced some heavy spray in tight spots. But it's fully covered and should be good to go!
15
BR8ES
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11/30/2018 10:15pm
Don't over Cerakote to the point of making the bike look like confetti... so far, so good.
1
Luxon MX
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12/12/2018 3:41pm
Been a while without an update as things have been busy! We're making more progress and more parts are starting to roll in. The Dal Soggio Spheres showed up yesterday from Brian at N2Dirt Suspension. That red color isn't going to go with the rest of the bike, so gotta strip that and re-anodize blue! More updates coming soon!


2
12/12/2018 3:45pm
Luxon MX wrote:
Been a while without an update as things have been busy! We're making more progress and more parts are starting to roll in. The Dal Soggio...
Been a while without an update as things have been busy! We're making more progress and more parts are starting to roll in. The Dal Soggio Spheres showed up yesterday from Brian at N2Dirt Suspension. That red color isn't going to go with the rest of the bike, so gotta strip that and re-anodize blue! More updates coming soon!


I was going to ask if Brian was going to be involved with the suspension at all. haha! How much longer until this thing is back together?!?!
Luxon MX
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12/12/2018 3:57pm
mattyhamz2 wrote:
I was going to ask if Brian was going to be involved with the suspension at all. haha! How much longer until this thing is back...
I was going to ask if Brian was going to be involved with the suspension at all. haha! How much longer until this thing is back together?!?!
I'm hoping to be riding this in a month, two tops. But things always take longer than planned!
1
12/12/2018 4:05pm
mattyhamz2 wrote:
I was going to ask if Brian was going to be involved with the suspension at all. haha! How much longer until this thing is back...
I was going to ask if Brian was going to be involved with the suspension at all. haha! How much longer until this thing is back together?!?!
Luxon MX wrote:
I'm hoping to be riding this in a month, two tops. But things always take longer than planned!
Ya I know how that goes haha. Can't wait to see the finished product
lumpy790
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1/5/2019 5:17pm
Luxon MX wrote:
Cerakote showed up yesterday. Got a few different colors so we can do the chassis, engine, calipers, and various other bits: [img]https://p.vitalmx.com/photos/forums/2018/11/30/306566/s1200_37_Cerakote.jpg[/img] I've never sprayed Cerakote...
Cerakote showed up yesterday. Got a few different colors so we can do the chassis, engine, calipers, and various other bits:



I've never sprayed Cerakote before, so why not start with the most difficult part of all? Putting the forklift to good use:





And once all the spraying was done I moved it into the office. This is the C-series Cerakote, so it is air cure. In a day you're supposed to be able to handle it and install parts, but full cure is in 5 days.



Overall it came out pretty good. A couple runs, but nothing terrible and mostly in non-visible areas. I was mostly concerned with getting good coverage over all areas so things don't rust, which forced some heavy spray in tight spots. But it's fully covered and should be good to go!

I like that color for the frame! Is Cerakote pretty heavy duty fighting wear?
Luxon MX
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1/16/2019 10:12pm
Long overdue for an update! Holidays, life, work, etc. have all gotten in the way...

Got around to making up a "custom" glide plate today. I've always been a fan of glide plates to protect the bottom of the chassis and to help, well glide, over things should I come up short, hit a rock, or similar. But I don't like the weight typically associated with the things! On our last 150 we used a modified TM Design Works skid plate, cut down for size and weight as it was huge (for mx). Plus it had really heavy brackets.

So for this bike we made up some lightweight tabs and welded them on to the chassis (quite some time ago) that are compatible with the TM skid plate. We then got a piece of fairly thin UHMW, traced out the shape we wanted (based on our last modified TM version), and cut it out. From there, we apply some heat, bend it into shape, and finally smooth out the edges and sand things smooth for an even(ish) finish. It's not the nicest looking thing, but considering it's job is to get beat up and it's hidden underneath the bike, I'm not too worried about it. Plus it's fairly lightweight at 0.75 lb including fasteners. A bit of a weight penalty, but it's something we feel is worth it.








1
Luxon MX
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1/16/2019 10:21pm
Now that the glide plate is on, we can start to re-assemble some things, which is a nice change. First on are the footpegs. We went with Pro Pegs on this build as they have an extra row of teeth vs. Raptor for only a few grams more weight and are a bit less expensive to boot.



Here you can kind of see the MotoHose T-piece installed replacing the stock t-piece that's heavy and a pain to deal with. The MotoHose unit is really nice and a must have if you take the bike all the way down to the frame. Plus Lumpy is a Vital member and a good guy, so win-win!



Now it's up on the stand and we're slowly putting on all the pieces. I'll get back on it tomorrow for some more progress.


5
JMX82
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Hyllykallio, FI
1/16/2019 11:28pm
Maybe adding some carbon fiber vinyl wrap on bottom of that glide plate would make it look better? . I did consider doing that for my build, but it ended up looking good even with out that. Did you check exhaust pipe clearance in front of the glide plate? I had to trim down mine after doing that because exhaust pipe comes almost straight down from the cylinder
Luxon MX
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1/17/2019 2:38pm
JMX82 wrote:
Maybe adding some carbon fiber vinyl wrap on bottom of that glide plate would make it look better? . I did consider doing that for my...
Maybe adding some carbon fiber vinyl wrap on bottom of that glide plate would make it look better? . I did consider doing that for my build, but it ended up looking good even with out that. Did you check exhaust pipe clearance in front of the glide plate? I had to trim down mine after doing that because exhaust pipe comes almost straight down from the cylinder
All clearances are good to go! Checked that before I started. I'll probably leave it, but I have another TM plate coming in case I want to change it.

Luxon MX
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1/17/2019 2:40pm
lumpy790 wrote:

I like that color for the frame! Is Cerakote pretty heavy duty fighting wear?
Not sure yet on the Cerakote, but it feels pretty tough so far. Should I get everything together and find it doesn't hold up all that good I can always tear it down and have it powder coated. Time will tell!
Luxon MX
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1/17/2019 6:55pm
Here's a quick shot of some of the titanium and aluminum fasteners/bolts/axles that are going into the build. These are sourced from a variety of manufacturers. There are some more not shown, plus more to come. I won't bother detailing each and every one since that's a lot of pictures! Most all the fasteners that offer a lot of weight savings will be replaced with Ti or Al and also the most visible ones simply because they look cool. There will be a few here and there purposefully left as steel for strength and durability reasons.


2
MotoRoss678
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1/17/2019 7:15pm
Luxon MX wrote:
Cerakote showed up yesterday. Got a few different colors so we can do the chassis, engine, calipers, and various other bits: [img]https://p.vitalmx.com/photos/forums/2018/11/30/306566/s1200_37_Cerakote.jpg[/img] I've never sprayed Cerakote...
Cerakote showed up yesterday. Got a few different colors so we can do the chassis, engine, calipers, and various other bits:



I've never sprayed Cerakote before, so why not start with the most difficult part of all? Putting the forklift to good use:





And once all the spraying was done I moved it into the office. This is the C-series Cerakote, so it is air cure. In a day you're supposed to be able to handle it and install parts, but full cure is in 5 days.



Overall it came out pretty good. A couple runs, but nothing terrible and mostly in non-visible areas. I was mostly concerned with getting good coverage over all areas so things don't rust, which forced some heavy spray in tight spots. But it's fully covered and should be good to go!
Incredible build! I was curious as to how you heated the whole frame for the “gas out” part of the preparation process? I’m thinking of doing this to my 2006 YZ 125 project and I can’t think of a reasonable way to perform that part of the process.
Luxon MX
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1/17/2019 7:59pm
Incredible build! I was curious as to how you heated the whole frame for the “gas out” part of the preparation process? I’m thinking of doing...
Incredible build! I was curious as to how you heated the whole frame for the “gas out” part of the preparation process? I’m thinking of doing this to my 2006 YZ 125 project and I can’t think of a reasonable way to perform that part of the process.
Thanks! Regarding the gas out process, it was simple, I just skipped it! The gas-out is nice to do if you have the capabilities, but not a necessity. I don't have an oven nearly large enough to handle that, which is the same reason I went with the air-cure Cerakote.
MotoRoss678
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1/18/2019 9:37am
Incredible build! I was curious as to how you heated the whole frame for the “gas out” part of the preparation process? I’m thinking of doing...
Incredible build! I was curious as to how you heated the whole frame for the “gas out” part of the preparation process? I’m thinking of doing this to my 2006 YZ 125 project and I can’t think of a reasonable way to perform that part of the process.
Luxon MX wrote:
Thanks! Regarding the gas out process, it was simple, I just skipped it! The gas-out is nice to do if you have the capabilities, but not...
Thanks! Regarding the gas out process, it was simple, I just skipped it! The gas-out is nice to do if you have the capabilities, but not a necessity. I don't have an oven nearly large enough to handle that, which is the same reason I went with the air-cure Cerakote.
Thank you for the clarification! I was hoping that was the case. I'm in the same boat concerning an oven big enough so I was stoked to hear that there was a series of Cerakote that air cures.
lumpy790
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1/19/2019 5:41am
Luxon MX wrote:
Now that the glide plate is on, we can start to re-assemble some things, which is a nice change. First on are the footpegs. We went...
Now that the glide plate is on, we can start to re-assemble some things, which is a nice change. First on are the footpegs. We went with Pro Pegs on this build as they have an extra row of teeth vs. Raptor for only a few grams more weight and are a bit less expensive to boot.



Here you can kind of see the MotoHose T-piece installed replacing the stock t-piece that's heavy and a pain to deal with. The MotoHose unit is really nice and a must have if you take the bike all the way down to the frame. Plus Lumpy is a Vital member and a good guy, so win-win!



Now it's up on the stand and we're slowly putting on all the pieces. I'll get back on it tomorrow for some more progress.


Awesome build and thank you for helping us develop specs for the new T hose design!
1
Luxon MX
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1/21/2019 12:05pm
One thing I don't like with the replacement t-hoses (any brand) is that they no longer fill up the hole in the frame so it looks a bit odd. We just happen to have an SLA 3D printer, so we whipped up some custom rubber grommets to clean it up a bit.

The printer basically solidifies a part layer by layer from a vat of goo. These printed out in about 6 hours, then they go into an alcohol bath to remove the excess goo, then into a UV chamber for curing, then the supports are cut off, and finally sanded smooth to create the finished part. Not as nice as a molded silicone part, but they will do the job and we didn't have to spend thousands of dollars on tooling to make it happen!








22
BR8ES
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1/21/2019 12:17pm
Luxon MX wrote:
One thing I don't like with the replacement t-hoses (any brand) is that they no longer fill up the hole in the frame so it looks...
One thing I don't like with the replacement t-hoses (any brand) is that they no longer fill up the hole in the frame so it looks a bit odd. We just happen to have an SLA 3D printer, so we whipped up some custom rubber grommets to clean it up a bit.

The printer basically solidifies a part layer by layer from a vat of goo. These printed out in about 6 hours, then they go into an alcohol bath to remove the excess goo, then into a UV chamber for curing, then the supports are cut off, and finally sanded smooth to create the finished part. Not as nice as a molded silicone part, but they will do the job and we didn't have to spend thousands of dollars on tooling to make it happen!








That looks great.
1/21/2019 12:25pm
Luxon MX wrote:
One thing I don't like with the replacement t-hoses (any brand) is that they no longer fill up the hole in the frame so it looks...
One thing I don't like with the replacement t-hoses (any brand) is that they no longer fill up the hole in the frame so it looks a bit odd. We just happen to have an SLA 3D printer, so we whipped up some custom rubber grommets to clean it up a bit.

The printer basically solidifies a part layer by layer from a vat of goo. These printed out in about 6 hours, then they go into an alcohol bath to remove the excess goo, then into a UV chamber for curing, then the supports are cut off, and finally sanded smooth to create the finished part. Not as nice as a molded silicone part, but they will do the job and we didn't have to spend thousands of dollars on tooling to make it happen!








Any chance you're going to make these for sale? Look great!
Luxon MX
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1/21/2019 4:33pm
LumpDog841 wrote:
Any chance you're going to make these for sale? Look great!
Unfortunately not, they're just too much time and effort to offer up for sale as they'd be pricey. 3D printing is nice for one-off parts, but any sort of production just doesn't make much sense unless you've got a lot of time on your hands!
1
navalseabee
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1/21/2019 4:51pm
LumpDog841 wrote:
Any chance you're going to make these for sale? Look great!
Luxon MX wrote:
Unfortunately not, they're just too much time and effort to offer up for sale as they'd be pricey. 3D printing is nice for one-off parts, but...
Unfortunately not, they're just too much time and effort to offer up for sale as they'd be pricey. 3D printing is nice for one-off parts, but any sort of production just doesn't make much sense unless you've got a lot of time on your hands!
You could sell just the file, then we could utilize online 3d printing services.
2
Luxon MX
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1/21/2019 5:44pm
You could sell just the file, then we could utilize online 3d printing services.
Or we could just give it away...
https://luxonmx.com/resources/luxon-2019-ktm-frame-coolant-plug.zip

Unrelated, but there's a fairly useful bolt torque spreadsheet in that directory too:
https://luxonmx.com/resources/luxon-bolt-torque-calculator.xlsx
26
cdoggy81
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St. Petersburg, FL, USA
1/21/2019 7:03pm
Good stuff right there. Nice Luxon!
FiendzCC
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Murrieta, CA, USA
1/23/2019 9:03am
Laughing my ass off at how Billy just subtly flexes on all of Vital and our "builds" where we just bolt on parts. I'd expect nothing less of you just "whipping up" you own rubber grommets haha

I have some wheels that you should see tomorrow. Any chance you'd have time to whip up some clamps for our '02 CR?

3
Jrewing
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AU
1/24/2019 12:44am
That 3D printer looks like some Alien shit. Impressive

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