Charles,
I know you have better things to do but I'd be VERY interested in your preparations for this endevour. I noticed you tore the bikes down to the frames and had them recoated. Was there a specific reason for that (gusseting, xray etc) or did you just want a different color. I wouldn't want to get any trade secrets for free but some of the changes - especially to the KTM's would do wonders for your fans. It would suffice it to say "send the head to Cycle Playground because they proved their worth" or "We decided on Talon hubs because not only did thy make the bike look sick and were free but actually shaved a couple ounces off". It would also be good to hear the stories of licensing and entries to the series. Most non-Pro riders don't know the half of it!
Maybe an interview of YOU, by one of US. Now that would be cool!
I have no problem with that and I would love to share details about the entire effort with you guys. It's tough doing everything by myself and time is hard to come by right now. Hopefully I can get something up in the off week after high point this weekend, between testing/tuning sessions.
A few quick answers:
We had the frames Powder coated, and a little foam fill for damping. Swapped the metal T coolant fitting with a single piece silicone unit. (The stock coolant T is the ONLY part I didn't like on the KTM's). It just looked like it belongs in plumbing section at Lowe's, 3 piece threaded pipe and T fitting. I'm much more comfortable with the single silicone T.
Cycle Playground does have a great reputation with KTM's, we have been dealing with them for a while. Having them help wrench at the races is a huge added bonus.
For the motors we went with a broad powerband, built for reliability. (There is still plenty of power to squeeze out if we wanted/needed it.) Doesn't look like we do

Case clean up, matching, intake/exhaust porting, altered port timing and a re-cut bowl is about as far as the motor work has gone. The PWK has a 37x39 oval bore.
All bikes are built the same, except Robby's has the Factory WP A kit. The rest have some goodies inside but not like the 82.
The wheels are for looks, but also much stronger than the stockers. (And they weren't free)

We are using the DT1 aluminum filter cages, which we HIGHLY recommend for the KTM owners. They seal much better and offer great piece of mind. I know I have read some issues with the KTM stock plastic design sucking dirt if not installed correctly. Feel free to ask anything you would like to know and I'll answer as I can.
I finished freshening them up for High Point last night, heading out to do some testing/tuning/filming with Robert Kraft here in a bit. We'll have some GoPro/Video and pics coming.
Everyone that has twisted the grip on these bikes gives the same reaction.. Fast and Fun. That's what it's all about right?
