2020
“MM-300” Custom Build

The transformation of a 2014 KTM 300 XC-W Six Days enduro into a sleek, neo-futurist–inspired street tracker with minimalist finishes—combining reworked suspension, 19" dirt-track wheels, and custom hand-formed aluminum bodywork to merge street aesthetics with off-road DNA.

All work outside of upholstery and CNC-machining was completed by myself. This includes:

  • All up-front designwork

  • Hand-formed aluminum bodywork

  • TIG weld-fabricating a new aluminum rear subframe

  • Seat pan and foam carving

  • CAD for 3D printed carbon fiber headlight

  • New electrical harness

  • TIG welded stainless steel exhaust and muffler

  • CNC polycarbonate LED tail light with integrated turn signals

  • CAD for CNC wheel adapter hubs

  • Final body prep and paint

 

Aluminum Bodywork Forming

With each build I aim to pick up a new skill. For this project I took on learning to hand form sheet metal bodywork.

Once the client settled on the above design direction I enrolled in metal shaping classes with a Master of the medium, Cristian Sosa down in Las Vegas. There he taught the process of wire-bucks and paper templating I’m using to create the KTM’s bodywork in the attached gallery.

The metal used is .063” Aluminum 3003 H14

Headlight Design

Designing a custom headlight bucket and mounting bracket to house a Hella Black Magic 500 lamp.

The final product would be 3D printed. I ran thermal tests with the headlight on for an extended period while mounted in it’s original enclosure. Using that peak temperature data and the knowing the material would also need to withstand UV and vibration, I selected a carbon fiber nylon composite. This material’s heat degradation temperature allowed for a good sized saftey margin while also have great UV resistance and moderate flexibility.

The design went through a few rounds of updates to optimize the adjustment notching and account for material shrinkage. The end result was used on both this build and the Ducati MM1000GT (here).

Tail Fabrication

While the main frame remained untouched, the tail frame was a completely bespoke part, fabricated with a mix of 6160 Aluminum tubing, plate, and sheet.

Seat Development

The seat pan was formed out of aluminum sheet, featuring bead rolled depressions for added structure. It’s installed with a hooking feature in the back of the tank, then 2-M6’s from under the tail.

The foam was carved from different densities; a medium density white for comfort with a higher density gray along the sides to ensure the waist line prevails after upholstery is stretched over top.

Custom CNC brass dies were cut to punch out embossed leather logos. The final upholstery was done in black leather by New Church Moto.

Wheels & Hubs

Custom hubs were designed to mate billet 19” flat track wheels to the KTM 300 with a supermoto fork spread. To upgrade the braking, an oversized 320mm Ducati front rotor was chosen due to it’s small bolt PCD, allowing the mounting hub to be smaller, lighter and less expensive to manufacture.