A customer approached us asking for a bespoke aluminium chain spoiler for his KTM Superduke 1290. A cardboard template and a picture of a design he liked were provided. We started working on this project right away, knowing it would be no easy task.

The model was designed in CAD to scale. We then 3D printed it to see if it looked good in person. After we were happy with the 3D model, we cut it into three components: the top, the sides, and the base. Due to the complexity of the geometry, planning was crucial.

We CNC machined a wooden press tool to make the recess in the top plate which we pressed and then cut to size. We then printed a template for the sides and bottom and cut them out of aluminium.

Once all individual parts were fabricated, we proceeded with welding and shaping the sides to the top and base plates. For strength, we welded them both internally and externally, as we would be grinding and polishing the finished part with no trace of welding visible.

After several hours of grinding we had achieved a finish on the part that both us and the customer were happy with. We then coated the parts in a stunning Orange Cerakote to match the KTM orange on the Superduke. We then added a high gloss armor clear to help with wear resistance as it would be very close to the floor.