GS500GS?

[Nudie]

I am beyond envious of your peg/shifter work. LMK if you want to make more to sell.

That's a pretty big compliment, thanks.

I think I read somewhere that Michelangelo used beer boxes to get the right shape before starting any of his masterpieces. So if it's good enough for him......

[gregjet]

"I think I read somewhere that Michelangelo used beer boxes to get the right shape before starting any of his masterpieces. So if it's good enough for him......"
I think you are thinking of Andy Warhol. Michaelangelo was Italian...he used wine casks...

Polyureathane sheeting is a brilliant material for prototyping.

[Nudie]

Ahh Warhol! I always get them mixed up! Their work is so similar

[gregjet]

So true...

[Nudie]

I spent all bloody day making a frame to mount the headlights. It's such a pain in the arse measuring, bending, fitting, swearing, making another, repeat a few times until you get one right. Then start again! Anyway Im fairly happy with it at this stage. I'll probably end up removing the bolts and riveting it instead.


Next I'm thinking of making a fibreglass fairing with a perspex screen on top. But I'm leaving this morning for work for a few days, so I'll have a bit of time to mull it over in my head and see what comes out

[gregjet]

Maybe not such a problem on the GS, as it isn't a bad vibrator, but extruded Al is notorious for cracking at the join edges. Especially if you have poprivetted it, here is a tip you may find useful. Lay 2 or 3 carbon fibre or glass ( or combination) over the sides of the frame/s that have the bulge on them  . You can do both. It takes the vibration loads and spreads them through the the layers and dampens the fatigue producing stuff. For that I would use tape rather than cloth as less wastage. Once you trim it it will look pretty good as well. Don't forget you have to use epxoy for carbon not polyester ( that's for anybody that is eating this , as it sounds like you may know that already.
You need to clean and sand pretty well though, or the bond tends to be a bit crappy.

[Nudie]

I was thinking if I didn't bond it to the frame, rather make it seperate and screw/bolt it on they would support each other and lessen the amount of vibration. It would also make it easier to adjust lights, access wiring etc if the fairing could be removed without taking off the frame.

Keep in mind I'm a crane driver, not an automotive engineer!

[Nudie]

I made (and tested lol) these engine protection bars a few years back for another Scrapheap bike, but they were removed before the bike was sold. I remembered the other day that they were still in the shed. So, looks like with a little tweaking they will save me a heap of work making new ones.


The middle and bottom frame clamps were made for a round frame, so will have to be squared off. The upper lug that bolts on with the engine bolt, just needs to be cut off and welded back on at the right orientation. I haven't tried yet, but I hope the R/H side is just as easy!
The crash bars were originally made for a Kawasaki ER5 and I'm amazed by how similar the two bikes are.


P.S. I'm sorry if I'm not allowed to mention that OTHER bike here

[Nudie]

I got a bit of fibreglassing done today. I really don't know what I'm doing, but it's fun trying.

[cbrfxr67]

"swearing"


good stuff here!  Hope you keep at it!  Really cool to see your progress,...

[Nudie]

So after 4 layers of glass, it was dry enough and I couldn't help myself so I peeled it off and started playing around. It looks like this now.


Don't judge me too harshly, it's a work in progress. I still have to work out the final shape, then smooth it out with body filler. I've got a guy who will paint it for me when I finish all the other jobs off. But before then I have an idea for a clear screen. Like everything else, I'll be making it up as I go.

[ShowBizWolf]

I always love me a fiberglass project!! It's amazing stuff, for sure.

Sweet progress, can't wait to see more

[gregjet]

" I was thinking if I didn't bond it to the frame, rather make it seperate and screw/bolt it on they would support each other and lessen the amount of vibration"
I wasn't suggesting you bond it to each other, rather that you use a layup to bond the frame itself together and speard the "hard points" where the vibration cracks the frame.
You are right though, the separate glass piece will help dampen the vibrations , but the vibration passing along the aluminium frame is what cracks it.
I like what you are doing though. Should be interesting and effective.

[Nudie]

Ahh that makes more sense. Thanks, I did think about using an adhesive on all the joined surfaces. A type of sealant/adhesive that would keep some of its flexibility to help with the vibration, but in the end we'll just have to see how it goes.
Thanks for your help all the same.

[Nudie]

Im less than impressed at the shape of the opening for the lights. It was a shitfight trying to work out where to cut the bloody thing. So I decided a bezel (if that's the right word) would cover up my mistakes. First I made a template in cardboard, then trace it onto some plastic panelling stuff that has been taking up space in the shed.


I've cut it out, but you'll have to wait til I get a bit of shaping done on the fairing. Then I'll take a pic and post it.
By the way, fibreglassing is painful. My hands are killing me. It's like electricity, you can't see it, but it hurts!

[Nudie]

So this is were it's up to at the mo'. Filling, sanding, filling, sanding etc. Im happy with the bezel, it seems to hide most of my mistakes.


More filling, sanding and it might look finished.

[Bluesmudge]

Great work!

[Nudie]

Work got pushed back a few days so I spent a bit of time in the shed. Almost finished the fibreglassing, maybe a bit more shaping and made a screen from some perspex I had. Not 100% happy with the shape, so some more work is required. I might go on to something else and come back to it later.


Keep in mind that it needs paint and all the bolts will be Allen head, so it will look different when finished.

[cbrfxr67]

man that's alot of work right there,....respect!

[gregjet]

Nice work. Looks effective . Should work for the purpose.

I suspect you are going to get some vortex shedding off the back of the screen.

Two things may be worth considering . A bit more angle back to direct some of the flow over you head, and spacing the screen away about 10-15mm from the fairing form. That will allow some flow up the inside and help reduce any vortex shed. It will also help stop it misting and also help demist it if is already is. That  will reduce the drag considerably.

Are you going to build a lower form as well?