2019-2020 KTM plastics on 2016-2018

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3/27/2020 3:06 PM

I know there were threads about it awhile back. But with being quarantine and local tracks closing, I’ve had time to give it a shot.

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So, I have a 2018 125 SX seen above, I also have a 2018.5 450 SX-F FE. I wanted to be able to run the newer style plastics on both bikes. I bought a 2019 fuel tank and subframe. And used the plastics from my factory edition just to mock it up. I had to do some trimming on the radiator louvers to get the shroud bolts to line up. Also, had to remove the rubber grommets that hold the tank on the side of the frame. Other than that, everything else lines up.
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The only other modifications that need done is the mount for the silencer. The brackets on the 18/19 subframes are different. My solution was to make a new can and drill new holes for the mount. Luckily I had access to a faro arm 3d scanner, made a cross section imported that into cad and made an internal mold that I’ll wrap in carbon and remove the mold. Drill the holes and rivet the bracket back on.
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When it’s all said and done, much cheaper than buying a 19-20 125 SX. And I still get to have an orange frame that matches my 450. Win win in my book. Let me know what you guys think.

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3/27/2020 3:25 PM

Great work!
This is good info!

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3/27/2020 5:57 PM

Lol, I've got a 2018, and if you showed me 5 newer orange bikes I couldn't tell which one was 2019

Really cool project, the silencer bracket was sweet.

That 18.5 looks nice.... got me thinking about a 450 smile

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3/31/2020 6:55 PM

So, since the mount for the exhaust are at different location on the 2018 vs 2019, I have to relocate the mount in the silencer to line up with the subframe. Figured I could make it a little more trick. So I finished up the mold (on the right), wrapped it in carbon with high temp epoxy. Used +/- 45 bias for some added stiffness, 3 lays, and she’s pretty stiff. Going to coat the outside in epoxy, let it cure, and wet sand it to get a really good surface finish. Then cut it to length, drill all the required holes, and we should be good to go.

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4/4/2020 11:50 AM

Thoughts? 🤔 💭Photo

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4/4/2020 1:34 PM

Millerrr973 wrote:

Thoughts? 🤔 💭Photo

Waaaaay good bro!! 👍

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4/5/2020 11:12 PM

Very nice! What did you use for the air boot?

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4/6/2020 9:44 AM

mwmx54 wrote:

Very nice! What did you use for the air boot?

The 2018 air boot still works with the 2019 airbox plastics. It lines up with the carburetor perfectly.

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4/6/2020 2:16 PM

End result of the silencer. Pretty happy with it, could still use a little more wet sanding but other than that, all good.

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