Your KTM heat shield components are in the mail (well, in the next day or two anyway) and here is how I put the prototype together. Kent, you don't know me well enough, but in a brief moment of clarity and motivation, I decided to construct some edge protection for the guard so that it didn't scratch my already scratched muffler.
 |
| Cutting slot in AL tubing. |
I used 1/4" OD aluminum tubing and split it along the the length with a dremel and fiber disk. I did not include the aluminum tubing in your kit (I know, what kind of guy gives an incomplete gift) because, #1 I didn't know if you wanted to do the mod and, #2, I didn't have any more tubing. I cut 2 lengths of 9" tubing then, using a flat board rolled it over the tubing on the garage to straighten it out. I then chucked it up in my tiny lathe to hold it in place while I made the cut. If you don't have a handy, dandy lathe then I would use a hose clamp and clamp it to a piece of PVC tubing (or something equivalent) and clamp the PVC tubing in the vice to hold the AL tubing.
 |
Dremel tool cutting the slot for the
clamp.
|
I filed the cut smooth and if you wanted to ( when my laziness returned, I opted out of this part) you could hit the tubing with the buffing wheel and it'll shine like the stainless.
 |
AL tubing slipped over the edge
of the shield.
|
Next, use the Dremel and cut two slots a little wider than the, 4"-5" hose clamp, in the shield right where it bends. Don't do what I did and attempt to cut the slot in the center (length wise in the shield). I would make the cut 1/3 the length. If you cut it in the center you'll find the clamp will hit the tab where the muffler mounts to the frame and doesn't give you the adjustment you might need to position the guard where you want it. Ask me how I know this.
I chose to use only one clamp instead of 2. I think you'll find one clamp holds it very tight making the second clamp unnecessary. At this point you just slip the AL tubing onto the shield and mount it where you like.  |
Clamp screw positioned so it doesn't
hit the tire.
|
When tightening the clamp make sure the screw on the clamp in on the underside of the muffler and not in a position where the wheel could possibly hit it during full compression. It probably won't but I didn't feel like removing the shock to test it and find out.
 |
This is not the final position for mine.
It will probably be positioned
closer to the rear of the muffler.
|
 |
The small air gap is all that's needed
keep the shield cool and your
bags from melting.
|
After that you could put little squadron stickies that say "DOG" or, what was Kent's moniker? "Blowout"? I don't remember. :-)
Have fun.
