Setting new standardsTo design a reliable part, designers and engineers need to have data. In Aurora we firmly believe that changing the material or manufacturing method, means that the design should be different. Since the beginning, our towers do not mimic composite towers and for a good reason. By definition, if two towers have the same shape but they are made from different materials, one of them has to be poorly designed. That is mainly because there are data missing and designers and engineers have no ground to base their design.Data logging has been around since the 60s when Formula 1 cars were logging engine data in analogue tapes.As years went buy, Formula 1 cars used this technique to optimize their engines by running virtual races in a laboratory facility in Japan knowing the exact time that the driver was downshifting, accelerating, breaking, air temp, air pressure etc.
DESIGNAll these data from our database are used by our engineers to create virtual simulations of the worst-case scenarios, based on values from out data logging activities. The parts are put through virtual testing before they even get manufactured. Static and dynamic analyses, impact, and fatigue tests, as well as topology optimization are all performed on high end PCs dedicated to Computer Aided Design (CAD). If the parts fail at this stage, there is no reason to even turn the CNC milling machine on.Having optimized the parts, 3D printing commences. All the parts are printed in high quality Alumide (Polyamide with a low percentage of aluminum particles). This allows us to have a functional model to test on the bike and perfect he ergonomics, cable routing, and test the bike in real time without producing expensive aluminum prototypes. The designers make the final touches at this stage, as the printed parts can be drilled and threaded. For the tower alone, both the tower and the frame clamp, went through 12-15 iterations to get to the final, optimized design that you see in the pictures.Traditionally spacers are used in all the navigation towers, not only to connect the pieces together, but increase the stiffness of the assembly. Optimizing the stiffness by designing each part individually in 3D, spacers are not necessary anymore. The main tower is only, 3 parts. Easier to maintain, access and service.
MANUFACTURINGThere are different manufacturing methods in all the parts that we have on our motorbikes. Welding, Laser cutting, Sheet bent parts, 2D milling, 3D milling and others. 3D milling is one of the most complex, but also one of the methods that produce high quality parts. The head clamp and the navigation tower are produced by 3D milling, allowing us to optimize the thickness of the material, maximize the strength and minimize the weight of both parts. Machined out of a solid block of aluminum (40 or 50mm thick!) , these parts are strong where they need to be, while as the assembly is simpler for the end user.
WARRANTYAll that homework comes with a warranty that is unprecedented in the rally sector. When we got involved in navigation tower design, as early as 2014, we quickly understood that this journey is not a walk in the park. We developed one of the first multi-material towers and the first 3D CNC clamp in the industry. And we backed it up with a lifetime warranty. Today, we are setting new standards in the industry.The CNC tower parts and the CNC frame clamp on this kit are guaranteed for the life of the product. What is new? We always want our customers to be safe and reach the bivouac or their traveling destination and make repairs there. Even if they crash. Design with crash in mind is a whole different story. To that end, these parts are guaranteed against breakage. For the life of the product. Crash it, if you will. These parts will never give up!
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Dakar Proven Reliability
Dakar. The toughest rally in the world by far. KTM. A brand with 18 wins in that very race. A rally bike like no other. The pinnacle of rally race engineering. OEM parts from that winning rally bike are installed on our kit. Screen, fully legal LED lights, Light mask, stone guard and the screen accessories are all taken from the KTM Rally Factory Replica. Not only you will be safer, but if you need spare parts, you will be able to get them from a local KTM dealer worldwide! We went a step further. We ditched the plastic Nylock safety nuts from the tower. Why? Because the Nylock nuts can be used only once and usually these directions are not followed. There are special clutch-like washers and new safety nuts that will make sure that the parts will go through the toughest of conditions without moving from their pre-defined position!