The MM-300 is a ground up custom street tracker, built on KTM's 300XC-W Six Days chassis. The build features a wide range of manufacturing methods from old school hand formed sheet metal to cutting edge carbon fiber composite 3D printing.
I used 1/8" welding wire to map out the design of the gas tank, side panels and radiator ducts directly on the frame. Once that was complete I wrapped the framework in masking paper, then used those pieces as templates to transfer the design to sheet metal. The benefit to using a wire form instead of a solid buck (clay / wood) is you can see through it to check how close your metal panels are during the shaping process. I hand formed all the metal bodywork from 3003-H6 .063in aluminum.
The design intent sketches at the start of the project are only a 20 foot view. Throughout the build process I break out many smaller areas as their own mini design projects. Here are a few of those one-off parts.
Above: A PVA test print of the headlight bucket and bracket. The test showed that plastic shrinkage altered the dimensions a bit so some adjustments are being made. The final will be printed in a carbon fiber and nylon composite. The CF/PA composite was chosen for it's high heat degradation temperature and vibration resistance. It's being printed on a Rasie3D Pro2 printer.
Above: This project was about detailing in the tail section. Exhaust routing changed to this under tail placement due to ergonomic issues when trying to run it along side the bike (like in the original rendering). The metal pieces for the wing and subframe gussets were water jet from 1/4 inch 6061 aluminum. The duck-bill heat shield was made by hand. The tail light lens was CNC cut from polycarbonate and then sprayed with a translucent red clear coat. A 25-LED light strip fits into the backside of the lens.
Above: For that "street tracker" aesthetic the bike is sporting 19 inch forged aluminum billet wheels from Roland Sands Design. In order to mount these to the KTM I had to design custom bolt-on hubs. The larger hub set is for the rear and was designed to utilize the stock KTM rotor and sprocket bolt patterns. The smaller hub set is for the front and was designed with a Ducati 5-bolt rotor pattern. The Ducati 5-bolt pattern is on a much tighter diameter meaning the hubs can be made smaller and therefore lighter. The Ducati Brembo rotor is a floating 320mm; a big upgrade over the stock 270mm KTM solid rotor.