UPDATE: Having fun with fiberglass - seat cowl [pic very heavy] [FINISHED]

Chanse · June 23, 2009, 07:30:42 PM

I would actually try to fab some metal tabs that match the profile of those then sandwhich them in the fiberglass, if you put any pressure on those they will snap, its awefully thin. Ive done quite a bit of fiberglass works and I can tell you 9 out of ten thats not gonna hold up to high speeds or someones arse pushing back on it from readjusting or hard accelleration. other than that great job so far, for a noobie to the glass. it usually takes a while to get the hang of it.

kml.krk · June 23, 2009, 08:09:58 PM

Quote from: dohabee on June 23, 2009, 07:12:07 PM
very nice! do those tabs stop it from sliding backwards as well as forwards?

the lip that holds the seat stops from sliding forward, and those other tabs stop from siding backwards.

Quote from: Chanse on June 23, 2009, 07:30:42 PM
I would actually try to fab some metal tabs that match the profile of those then sandwhich them in the fiberglass, if you put any pressure on those they will snap, its awefully thin. Ive done quite a bit of fiberglass works and I can tell you 9 out of ten thats not gonna hold up to high speeds or someones arse pushing back on it from readjusting or hard accelleration. other than that great job so far, for a noobie to the glass. it usually takes a while to get the hang of it.

I already broke one off...

I will redo them both tomorrow

Chanse · June 24, 2009, 06:40:17 PM

That sucks... lol I guess I didnt get my warning in there quick enough. sorry, to be on the safe side I would do what I mentioned above and do the single bolt in the grab rail I described for added security. It would be a shame to go down the road and have it blow off and get run over or something, after putting all that work into it. One visible bolt wont kill the look.

kml.krk · June 24, 2009, 09:21:47 PM

the only problem is that there is no grab rail anymore...
I removed it, otherwise the cowl would not fit or would have to have totally different shape.

BUT I can use the screw on the underside and screw the cowl to the seat. It will prevent from flying off and will not be visible

Chanse · June 24, 2009, 11:38:05 PM

unless the tab breaks again.

joker79507 · June 25, 2009, 03:50:08 AM

Quote from: Chanse on June 24, 2009, 11:38:05 PM
unless the tab breaks again.

Man, your name should be Debby Downer. jk lol

Chanse · June 25, 2009, 09:30:45 AM

Sorry to be soo negative but I always think of the worst and prepare for it then when it works out fine I chalk it up to preperation and experience... lol if it goes bad, that reaffirms my need and compultion to use gorrila welds instead of popsicle sticks and glue... lol

Chanse · June 25, 2009, 09:33:01 AM

beings how its fiberglass you can cut out the space where the grab bar would be, build it up a little then pull the design back towards the tail to give a raised T kinda look, that would make the profile kinda stand out a little and give it a more custom look. just a thought.

kml.krk · June 25, 2009, 05:59:02 PM

thanks for ideas Chanse, but I already figured something else

Instead of tabs I used nuts and bolts; the nuts are "glued" to the cowl using fiberglass and resin and I believe it is very strong. In fact I tried to brake them off by hand and I couldn't.

Now I slide the seat in the lip on the back - just like before, but then instead of forcing it to slide under those tabs I now screw 1 bolt on each side of the cowl (nuts are where the tabs used to be)

here are the pics of what I am talking about:

1. cowl attached to the seat using new mounting system

2. close up on the nut and bolt

PS. I have to round the edges of those bolts, because they touch the fairing a tiny bit, and I don't want it to get scratched.

cheers
KML

vhmpyr · June 28, 2009, 11:34:39 PM

Just wanted to say good job and you're welcome...you made a seat cowl and did almost exactly what I did when I made mine...At least this time I dont have to make another one since you already post the " how to "....

kml.krk · June 29, 2009, 07:48:21 AM

Quote from: vhmpyr on June 28, 2009, 11:34:39 PM
Just wanted to say good job and you're welcome...you made a seat cowl and did almost exactly what I did when I made mine...At least this time I dont have to make another one since you already post the " how to "....

thanks and you're welcome too

I told you in your thread that you inspired me and that I was going to make my own. I never lie

cheers

Chanse · June 29, 2009, 04:29:47 PM

Just a word of caution on that... yeah I know I'm a pessimist, cut a couple of pieces of fuel line or rubber hose that just slip over those bolts so that they don't tear the vinyl over time. the vibration will make them eat right into the seat pan.

Chanse · June 29, 2009, 04:30:27 PM

Oh yeah and good job, sorry I thought I could give a word of praise in there after all the hell I put you through. lol

kml.krk · June 29, 2009, 04:48:36 PM

that's actually a great idea with the hose!
I have some spare in the garage so I'll definitely do that once I get back home (I am fryin' my ass in FL at the moment

)

kml.krk · April 04, 2011, 08:10:23 AM

It is finally finished.
Phew... it only took 2 years to do it...
(some pics are overexposed as I took them with my cell phone - DSLR battery was discharged...)
It was a great excuse to finally thoroughly clean the bike. Last time it was that clean was when I bought it...

I may add some decals on the side of the cowl, I haven't decided yet. It will probably take another 2 years to come up with something...

steezin_and_wheezin · April 04, 2011, 08:47:06 AM

looks incredible!!!

hope the final product of my cowltech looks half as good as yours does

Pictory · April 04, 2011, 09:30:30 AM

I've been lurking this thread so I wanted to say bravo and thank you for the step-by-step!
Very informative and the final product looks really good!

RSK70 · April 04, 2011, 10:21:17 AM

new summer project

Nice work looks really good and nice smooth finish. Did you hand sand or use a power sander?

Also, what kind of handguards are those? Like the look and after this cold end of fall/ winter am looking to get a set for my bike. Thanks

kml.krk · April 04, 2011, 05:33:56 PM

thanks for positive reviews!

Quote from: RSK70 on April 04, 2011, 10:21:17 AM
Nice work looks really good and nice smooth finish. Did you hand sand or use a power sander?
Also, what kind of handguards are those? Like the look and after this cold end of fall/ winter am looking to get a set for my bike. Thanks

All hand sanded. Lots of work but lots of fun too. I was making a cowl while I was unemployed so I had some extra free time on my hands.

Those handguards are V-Strom handguards. I got them on ebay for about 60 bucks shipped. They are worth the price in my opinion. First of all they offer extra protection agains rocks or other flying objects and also great wind protection which helps a lot during winter days.

Right one fits with no modifications.
Left one requires a little bit of work but it's nothing very difficult. Bolts are all good size, so all you have to do is a little bit of cutting and grinding (cutting and grinding is applied to the handguard so there are no permanent modifications to the bike).

Let me know if you buy them and have difficulties installing. I will take some pics so you will know what to do!

ver4 · April 05, 2011, 09:18:08 AM

Looks good.

Is that about a 10 HP increase?

News:

UPDATE: Having fun with fiberglass - seat cowl [pic very heavy] [FINISHED]