Designing the Hidden Stuff

Progress on the NX650-R has moved into the part of the build that no one really sees but makes all the difference in how the bike feels. I have been deep in the electrical system, trying to hide as much as possible and keep the lines of the bike clean. The goal is simple: no visible clutter, no random boxes, no wires hanging in the wind. Everything should disappear into the frame.

To make that happen, I started modelling every single electrical component in 3D. CDI, regulator, starter relay, battery, connectors, everything. It might sound a bit obsessive, and honestly it is, but having accurate models lets me design trays and mounts that actually work instead of guessing. It also lets me play with placement and spacing in Fusion 360 before I commit to anything on the bike.

Once the layout felt right, I moved on to 3D printing the custom trays on my Bambu Labs P1S using ASA. There is not much load on these parts, so strength is not really an issue. What matters is fitment, airflow and keeping everything locked in place without being visible. ASA handles heat and UV well, and the printer hits the tolerances I need, so it is a perfect combo.

This is the side of a build that takes way longer than it looks. You can spend hours adjusting millimeters on a screen just to make sure a wire can pass cleanly or a connector can be unplugged without removing half the bike. But these little details are what make the final result feel intentional instead of thrown together.

There is still more testing to do, and I will cut grooves for wire routing to clean it up even further. Once that is done, the electrical layout will be in a good place and the rest of the system can finally start going together.

The progress may look slow, but each detail now saves me from having to redo things later. That trade-off is worth it every single time.