2013 CRF450R supermoto conversion
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Thread: 2013 CRF450R supermoto conversion

  1. #1
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    Default 2013 CRF450R supermoto conversion

    Hey guys, now since the husky is gone, I hope you didn't think that I am gone also. Here is my new build. This time it will be a pure racing machine.
    Went the 450cc way, plenty of power with a serious weight advantage.
    In the beginning of this summer I bought this:



    First things first, all the rubbish stickers have to go.



    It is only logical that before even start the conversion, one has to properly test the thing. ..both pigs looking for mud





    A quick comparison: 2013 model was excessively regarded as the best CRF up to date. So here is my opinion,
    It might really be true, but nevertheless 2008 was still a blast, it might handle not as good but the raw power it delivers with a built head and carb was enough to leave the twin piper in the dust while at wide open throttle. But never fear, the potential is all there, it just needs some work.
    The chassis handled really well, indeed like it has been regarded to. The bike felt balanced and delivered the power really smoothly.
    I hope this conversion succeeds!

    To be continued...

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  3. #2
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    awesome! looking forward to your build. i am also building a crf/cr race bike=) 2010 crf450 chassie with cr250 motor
    09 HUSQVARNA 450RR
    CRF450SMRR _ Parted out
    Husqvarna510smr_parted out
    CR525AF dirty
    BRP XR650R -traded=(

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    Suuuuuubbbbbbbscribed.
    06 husqvarna SMR510-Street/Some Track
    Honda 2005 CRF450 sumo track
    09 Husqvarna SM610 (sold)

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    2005 KTM 525SXM - stolen
    2004 KTM 450/525SX Project.............

    Riding Game: 5 complete
    We're not here for a long time. We're here for a good time.

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    So once everything is tested, here follows ToDo list:
    - clean and service the shock absorbers and prepare them to supermoto spec
    - check all the suspension bearings
    - get rid of all the old parts scheduled for replacement

    And the disassembly follows:












    A few things I did not expect, one of the front shocks was leaking, as it later turned out, it had a slight dent, and also one of the twin pipes was a bit hit.
    All the other stuff was minor..

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    So the shocks went to my buddies shop for servicing and supermoto spec configuration, while so, I decided to service the rear linkage.








    All the bearings looked fine. Seals fine, no rust, only minor wear. Everything lubed and assembled. Did not touch the main fork bearings because in most cases it is not necessary, they are usually fine. However after reassembly there was still a slight play somewhere in the linkage bearings. It is most likely the three way rod, which will be completely rebuilt after this season.

    While the shocks are being serviced, its time to gut the pipes.









    Requires some special tools for taking care of the exhaust.

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    Alright, back to the pipe!! All the special tools have been made, check out what's been done.





    Here only a part of the process is visible, but it should be enough to give you the idea behind it.













    Splendid!! The main work has been done, pipe has regained its prior form. Do you see the UFO?



    To time advance to the next level.















    And finally, the finished product! As good as new.




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    Great work on those pipes!
    2008 wr250x (sold)
    Saving for a 2012+ wr450

  11. #9
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    Wanna check out our secret cleaning weaponry?



    Find one difference



    And aside from this, I accidentaly bought this, unfortunatelly they don't fit 13' but it should fit like a glove to 09-12 CRF450ies.
    Selling it for the exact same price as bought. 55 EUR shipped to EU.


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    Is that a homemade sand blaster? Some good tips

  13. #11
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    Quote Originally Posted by syco_ste View Post
    Is that a homemade sand blaster? Some good tips
    Yes Sir!!!! You are right

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    Haha. Awesome.

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    Now, about some a bit more shiny things,
    Here's most of the parts saved up for the build except for the slipper clutch which is being awaited.
    - FaBa wheels kit
    - Beringer front brake system
    - EK Chain + JT sprockets
    - Mitaka clutch basket
    - FaBa triple clamps (adjustible)
    - Revalved, serviced OEM suspenison



    The triple clamps first.


















    These triple clamps give you the ability to adjust the front fork angle in boundaries of +- 1.5 degrees which translates to approximately +- 15mm of wheelbase change, it also changes the trail. It also gives you the ability to place the handle bar in several different positions both closer or farther from the seat. It has the standard offset 16mm in the middle position. It can be changed in boundaries from 22 to 10 mm. This offset change suits perfectly for MX also. The width between fork centerlines is 200mm. The manufacturing quality looks good enough, pretty robust joints and all other critical areas. We will have more opinion on this once we start to ride it.

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    Here the triple clamps are in place with the handle bar mounted.
    Like I already mentioned earlier, one of the front shocks was damaged on the back side, apparently the previous owner had crashed it during a race and someone ran over or into the bike hitting the backside of the shock cylinder. This however has been fixed with polishing and done so well that you can't even visually find the dent anymore, hence it's useless to try and take pictures
    Polishing is widely used for fixing various stem damages that don't have sharp edges. That's the best way to go.








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    The clutch!! Part one..

    So why Adige APTC?
    Unfortunately it proved to be very difficult to find a rider that is actually racing the clutch, so obviously we didn't. It is hard to get accurate feedback in this case because most of the riders only use or have used one clutch and have their opinion about it. That is why it is useless to try and compare it to something else.
    After an extensive investigation we have finally decided to choose adige. First of all because it was relatively cheap, second the tech behind it lightens your lever a bunch. And third, the construction idea is completely different from all other manufacturers though simple. It functions basically like a screw and a nut (the engine cranks a screw, and the wheel is connected to a nut, spin it in your head and see what happens.) It may not have such good looks because it is cast and has a silly first impression look, only three springs. That might be the reason why not so many people choose it over something else.
    The downside however is that the only compatible discs are adige themselves.
    And so, the I.t.a.l.y. begins here, after four tiresome weeks, the clutch finally arrived





    Whoah!! What a box!! You'd expect something like this from JohnDeere instead



    Let's see whats inside the belly.



    Gotta pull the old guts out first.





    Judging by the look of this, the previous owner had REALLY raced this thing hard, what an animal..






  18. #16
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    Continuing with the "disassembly" of the stock raped clutch and it's successor. (Mission clutch part 2)





    Thought I'd press it out with a vice. Believe it or not.. That was the only way to do it
    Honda engineers have done an outstanding work to screw with the business of aftermarket clutches...



    Here's why:









    Pressed the gear in the MITAKA basket using a hydraulic press. Looks nice enough!









    Hahaha!




































  19. #17
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    What's up with red anodizing spot on the inside of the triples ?
    09 HUSQVARNA 450RR
    CRF450SMRR _ Parted out
    Husqvarna510smr_parted out
    CR525AF dirty
    BRP XR650R -traded=(

  20. #18
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    I think it might be a casting deffect. Their parts seem to be cast and later cnc machined. However it is so slight that you can hardly feel it with your fingers.

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    Time to throw together some stuff that has been cleaned/fixed.
    The mysterious substance used in the video I posted earlier was SODA, but most of you probably noticed that already. These the parts!





















    Had to come up with some kind of spacers, as much as I was able to pull the pipes apart, the idea is for the rear wheel to fit between them during landings or other serious situations. Looks like a tight fit, but it should do!!








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    looking good!
    http://www.supermotojunkie.com/showt...procket-spacer

    Get your crf lined up, Sprocket spacer available pm me!

  23. #21
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    Wheels!!
    As you can see, these are FaBa tubeless 17'' both front and rear. Look nice don't they?





    Now let's throw some Michelin slicks on 'em
























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    Had to make a few corrections/adjustments for the front wheel for the wider triple clamps to take the brake set
    So why spacer and not bushings under the brake support? The thing is that every bushing requires longer support screws and this adds leverage making it easier to bend them which results in the support floating under load. The spacer on the other side has special lips that help this issue. Even if the crews become loose, the disc will remain centered on the hub. Most spacer manufacturers don't cut them.



























    You can see here that the brake disc is located almost perfectly in the middle when compared to the caliper.


  25. #23
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    To everyone: Here you go guys



















    A near future project! (this is only a test obviously)




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    Today was the first track day, have to admit, it was my first sumo track day as well.
    Heres a good picture of the track itself, location - very close to home (about 5km straight)
    This is one of those tracks that stood as far back as the soviet times in here.

    http://rullitis.lv/?project=sporta-u...leks-rullitis/



    Did a total of 4 sessions, each 6 - 7 laps long.







    Back home after an exhausting day in a Vanucci oven.




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    Mate, this bike is sexual. Nice work!

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    Quote Originally Posted by Dave2233 View Post
    Mate, this bike is sexual. Nice work!
    Thanx Bro

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    Yeeehhhaaa !!!!!........ Last Saturday was perfect practice day. Rode 5 sessions, totally about 90 laps.
    My ass is sore

  30. #28
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    Well done Andis
    09 HUSQVARNA 450RR
    CRF450SMRR _ Parted out
    Husqvarna510smr_parted out
    CR525AF dirty
    BRP XR650R -traded=(

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    nice honda logo in catch can

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    Quote Originally Posted by zazzaa View Post
    nice honda logo in catch can
    Did you mean this one ?? really ???




  33. #31
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    My first race


  34. #32
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    Well done!
    09 HUSQVARNA 450RR
    CRF450SMRR _ Parted out
    Husqvarna510smr_parted out
    CR525AF dirty
    BRP XR650R -traded=(

  35. #33
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    First race first place

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    Great work!

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    Quote Originally Posted by kba-pro View Post
    Here the triple clamps are in place with the handle bar mounted.
    Like I already mentioned earlier, one of the front shocks was damaged on the back side, apparently the previous owner had crashed it during a race and someone ran over or into the bike hitting the backside of the shock cylinder. This however has been fixed with polishing and done so well that you can't even visually find the dent anymore, hence it's useless to try and take pictures
    Polishing is widely used for fixing various stem damages that don't have sharp edges. That's the best way to go.








    Sweet bike! I have to ask. I bought a '13 CRF450R at the end of the year, rode it once on the track, and am going to overhaul it some this winter (Minneapolis). Was the triple tree worth the investment? Is there anything you wish you'd done differently? How about the clutch? The Adiago comes standard on the KTM SMR but it's a slipper clutch. Is yours a slipper clutch as well? Mine has a Hinson on it now, seemed like it worked well but I'm nervous if I ever get to the point where I'm "backing it in" to a corner...

    Would love to hear any thoughts or recommendations from you. The guy I bought it from is a Class A Supercross rider so suspension will be redone, bearings, rotors, new plastics, steel braided lines... Leads me to another question - my brakes felt pretty good, stock with new pads. I know the Beringer is badass and Magura is also sweet, but those are about $1K...

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    Quote Originally Posted by sullivjo View Post
    Sweet bike! I have to ask. I bought a '13 CRF450R at the end of the year, rode it once on the track, and am going to overhaul it some this winter (Minneapolis). Was the triple tree worth the investment? Is there anything you wish you'd done differently? How about the clutch? The Adiago comes standard on the KTM SMR but it's a slipper clutch. Is yours a slipper clutch as well? Mine has a Hinson on it now, seemed like it worked well but I'm nervous if I ever get to the point where I'm "backing it in" to a corner...

    Would love to hear any thoughts or recommendations from you. The guy I bought it from is a Class A Supercross rider so suspension will be redone, bearings, rotors, new plastics, steel braided lines... Leads me to another question - my brakes felt pretty good, stock with new pads. I know the Beringer is badass and Magura is also sweet, but those are about $1K...
    So far I am not a pro at supermoto, but the triple clamps were definitely worth the investment. Though there is one thing I would like to add - if you can get those directly from the manufacturer you will see a very good price. Otherwise if I had to bought them from a retail company, I think I would have skipped.
    The only drawback I see in the triple clamps was that they had messed up the bracket for steering damper. They made it too short which results in impossible mounting of the damper. Anyway, I have practically made my own with the correct length by now.
    The adjustability is really broad. About the clutch - a very good investment also, bought it directly from the manufacturer and yes, it is a slipper. It works very well and the best feature in my opinion - the soft lever. The STM clutch for comparison required the hands of a blacksmith. Up to now, I have seen no rear wheel boggle while downshifting whatsoever. It works just fine
    About the suspension - I actually think that the suspension of a supercross might work out really good with supermoto because of the fact that it is relatively stiff because of the higher jumps they make, I think they spend more of their time hanging in the air than on the ground Of course I have not tested this yet so I dont know for sure, but in my opinion it should work the best in combo with MX wheels (bigfoots).
    So far I have tried both - Magura and Beringer, and all I can say is that Beringer is the sweetest thing of them all. It works extremely precisely, minimal freeplay, and a very proportional braking power delivery. I had 195th Magura Master in combo with Braking supermoto caliper, the braking power was incredible, but the delivery did not stand close to Beringer. The OEM systems also require the hands of a blacksmith. The only competitor to a Beringer master in my opinion might be the high end of Brembo whose downside is that the only guys that service Brembos are Brembos themselves.

  39. #37
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    Quote Originally Posted by kba-pro View Post
    The only competitor to a Beringer master in my opinion might be the high end of Brembo whose downside is that the only guys that service Brembos are Brembos themselves.
    Great bike and very cool machining done! good job

    On the brembo comment, piston seal kits and such are available to anyone through multiple distributors
    masters and calipers are extremely easy to rebuild and service, like Very easy.. beringer is probable the nicest choice right after brembo.
    http://www.supermotojunkie.com/showt...procket-spacer

    Get your crf lined up, Sprocket spacer available pm me!

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    Awesome build! I'd really like to get some Faor triples on my bike! Have you had a chance to play with them and dial the bike in for each track?

    Why didn't you go with a 16.5" front wheel?

    You're right about the extra leverage on a longer bolt when spacing something like a caliper. Any particular reason you chooe to space the rotor ououtward? You could avoid adding any more leverage on those little rotor bolts if you go without the rotor spacer.

    My advice would be to mount the Beringer components as intended without any spacers on caliper or rotor. Then adjust the spokes to re-center the wheel which will account for the wider triples. It's the same concept as what I did on my Husky: When I replaced the offset OEM Brembo rotor with a flat Beringer rotor, I just shortened the axle spacer to locate the rotor back to line up with the radial caliper. Then I laced the rim back to center.

    Utilize those adjustable spokes!
    Last edited by J.R.; 11-29-2014 at 10:44 AM.

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    Quote Originally Posted by J.R. View Post
    Why didn't you go with a 16.5" front wheel?
    I got myself a 16.5" and I don't recommend going that route, many manufacturers are ditching the size... soon that tire will be discontinued. Stick to 17 inch.
    Michelin slick is the only way to go 16.5, at least the distributor I contacted are not carrying any longer.
    http://www.supermotojunkie.com/showt...procket-spacer

    Get your crf lined up, Sprocket spacer available pm me!

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    How's the bike running KBA?

    I wanted to see what you had done with the Honda steering stabilizer, it looked like you adapted it to the Faor triples?


    Quote Originally Posted by tyrap26 View Post
    I got myself a 16.5" and I don't recommend going that route, many manufacturers are ditching the size... soon that tire will be discontinued. Stick to 17 inch.
    Michelin slick is the only way to go 16.5, at least the distributor I contacted are not carrying any longer.
    BTW, 16.5's are going strong! Bridgestone and Golden Tyre are still offering them, but the tire to have is the new Metzler Racetec! in 16.5 and 17, 3 compounds each.
    Last edited by J.R.; 02-06-2015 at 11:29 AM.

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    Quote Originally Posted by J.R. View Post
    How's the bike running KBA?

    I wanted to see what you had done with the Honda steering stabilizer, it looked like you adapted it to the Faor triples?



    BTW, 16.5's are going strong! Bridgestone and Golden Tyre are still offering them, but the tire to have is the new Metzler Racetec! in 16.5 and 17, 3 compounds each.
    Hey J.R.

    Actually, this is the condition of the bike t the moment...



    Still getting ready for the next season, doing some minor improvements.
    Whats also going on is that the Honda is under research. I'm planning to really max it out for the 2016 season.
    I uploaded some pictures of the process.





    And here are some of the improvements for this season including the steering damper mount that you asked about
    Starting with handlebar spacers:







    And the HPSD mount:
    The FAOR triples originally had it designed too short. I was able to fit the damper but the steering angle had become limited which is pretty bad when the bike falls and hits the ground. It is going to rip the damper apart. The fix - manufacture it in the correct dimensions







    I have also been taking EFI system improvements pretty seriously for the past two years. Not only the programming issues, but also the mechanical/physical part of it.
    Thats about it for the moment.

    Regarding the statement you made about the 16.5 inches,
    I am sure that it can be sold just as good as the 17" in the states, but over here it's just not the same situation. Thus, they didn't want to give me a killer deal on it.

  44. #42
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    Looks like you've got some work ahead of you!

    Quote Originally Posted by kba-pro View Post
    And the HPSD mount:
    The FAOR triples originally had it designed too short. I was able to fit the damper but the steering angle had become limited which is pretty bad when the bike falls and hits the ground. It is going to rip the damper apart. The fix - manufacture it in the correct dimensions





    So you used the two existing holes on the front and added a third? (Where the silver aluminum part is bolted..) Why did you make the mount that way? It looks like your mount has multiple pieces for some sort of adjustment?

    BTW, are those the 12mm or 16mm offset triples? How are you liking them?


    Quote Originally Posted by kba-pro View Post
    Regarding the statement you made about the 16.5 inches,
    I am sure that it can be sold just as good as the 17" in the states, but over here it's just not the same situation. Thus, they didn't want to give me a killer deal on it.
    Is it hard to get 16.5" tires over there?

  45. #43
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    Quote Originally Posted by J.R. View Post
    Looks like you've got some work ahead of you!



    So you used the two existing holes on the front and added a third? (Where the silver aluminum part is bolted..) Why did you make the mount that way? It looks like your mount has multiple pieces for some sort of adjustment?

    BTW, are those the 12mm or 16mm offset triples? How are you liking them?



    Is it hard to get 16.5" tires over there?
    All of the black/red parts you are seeing in the picture are original, made by FAOR. I only re-fabricated the shiny aluminum piece, which since being longer than original, required the addition of another bolt to secure its position. The original piece was so short that it was only bolted from below the black sub-mount.

    Those are 16mm offset triples, I like everything about them so far, but unfortunately I have not had the chance to manipulate with adjustments yet but
    that's about to change this season, hopefully.
    16.5" tires are not as big of a problem as the rim was. Thus, like I have said before, over here it's also easier to sell it later on.

  46. #44
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    Quote Originally Posted by kba-pro View Post
    All of the black/red parts you are seeing in the picture are original, made by FAOR. I only re-fabricated the shiny aluminum piece, which since being longer than original, required the addition of another bolt to secure its position. The original piece was so short that it was only bolted from below the black sub-mount.

    Those are 16mm offset triples, I like everything about them so far, but unfortunately I have not had the chance to manipulate with adjustments yet but
    that's about to change this season, hopefully.
    16.5" tires are not as big of a problem as the rim was. Thus, like I have said before, over here it's also easier to sell it later on.
    Oh, so their CRF triples do have a mount for the HPSD but it doesn't work very well? Can you tell how much you changed the mount in order to work properly?

    Oh, so you guys can't get the 16.5" wheels very easy?? that's odd..

  47. #45
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    Quote Originally Posted by J.R. View Post
    Oh, so their CRF triples do have a mount for the HPSD but it doesn't work very well? Can you tell how much you changed the mount in order to work properly?

    Oh, so you guys can't get the 16.5" wheels very easy?? that's odd..
    Basically you can look at it like this,
    The only tire available for 16.5" rim is a sport tire, which is not street legal, thats why it is a bit more difficult to sell it afterwards.
    We had several reasons for going 17", another one being that it was not guaranteed, that I could get a 310mm Beringer brake disc which is easier to cope with the 16.5" rim.

    And about the HPSD mount, you got it correctly. I changed the overall height of it from 21 to 34 milimeters, and machined an additional bolt hole in it.

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    Awesome build

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    Yeeehaa!!
    The process of digitization is complete.
    How about a virtual model of a complete cylinder head?


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    Awesome Project!!
    Will be following for more updates

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    as an engineer i must follow this thread...

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    20

    Default FAOR HPSD bracket

    Are you thinking of machining the mount extension by any chance. I am in the process of purchasing a set of the FAORs, but I also want to ensure the use of the HPSD to its full functionality, as it had saved my butt a few times on these fast Spanish courses. Otherwise I will likely turn to XTrig for trips.

  53.  
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