So instead of losing track of all of my old posts and throwing information all over the place... I'm just gonna make a post from start to current of my bike. Some of this you may have seen, most of it you haven't.
*Pending
*Done
Currently where she stands:
* Massive Fender chop.
*.90 Sonic Springs in forks w/15w oil.
* Katana 750 Rear shock.
* LED bulbs in tail light.
* Blue gauge bulbs.
* LED mirror lights.
* LED turn signals/mirrors.
* Avon Road Riders (150 out back w/stock front)
* GS500F Headlight
* Pro Grip Grips
* Carbon Fiber Levers
* Carbon Fiber Bar ends
* Under-body spoiler.
* Vance and Hines SS Pipe
* BLACK superbike bars
* Jet the carb to 127.5 mains
* New Tank Pad
So here she was 1st day I got her:
(http://i26.photobucket.com/albums/c143/DannyMoped07/GS500E/IMG_0004.jpg)
(http://i26.photobucket.com/albums/c143/DannyMoped07/GS500E/IMG_0005.jpg)
(http://i26.photobucket.com/albums/c143/DannyMoped07/GS500E/OriginalTailLight.jpg)
After the first little group of mods:
(http://i26.photobucket.com/albums/c143/DannyMoped07/GS500E/IMG_0033.jpg)
(http://i26.photobucket.com/albums/c143/DannyMoped07/GS500E/Before-AfterTail.jpg)
(http://i26.photobucket.com/albums/c143/DannyMoped07/GS500E/Before-AfterSide.jpg)
Chin Spoiler:
(http://i26.photobucket.com/albums/c143/DannyMoped07/IMG_0001-1.jpg)
(http://i26.photobucket.com/albums/c143/DannyMoped07/IMG_0002-1.jpg)
(http://i26.photobucket.com/albums/c143/DannyMoped07/IMG_0005-1.jpg)
Installed SV650 Shock and did a shoot... kinda high in the rear:
(http://i26.photobucket.com/albums/c143/DannyMoped07/GS500E%20Shoot/CIMG0166.jpg)
(http://i26.photobucket.com/albums/c143/DannyMoped07/GS500E%20Shoot/CIMG0140.jpg)
Katana Rear Shock install/SV650 shock removal:
(http://i26.photobucket.com/albums/c143/DannyMoped07/GS500%20Katana%20Shock/CIMG0267.jpg)
(http://i26.photobucket.com/albums/c143/DannyMoped07/GS500%20Katana%20Shock/CIMG0264.jpg)
(http://i26.photobucket.com/albums/c143/DannyMoped07/GS500%20Katana%20Shock/CIMG0275.jpg)
New Lights:
(http://i26.photobucket.com/albums/c143/DannyMoped07/CIMG0479.jpg)
(http://i26.photobucket.com/albums/c143/DannyMoped07/CIMG0488.jpg)
New Light:
(http://i26.photobucket.com/albums/c143/DannyMoped07/CIMG0500.jpg)
(http://i26.photobucket.com/albums/c143/DannyMoped07/CIMG0494.jpg)
New Tires:
(http://i26.photobucket.com/albums/c143/DannyMoped07/CIMG0502.jpg)
(http://i26.photobucket.com/albums/c143/DannyMoped07/CIMG0481.jpg)
(http://i26.photobucket.com/albums/c143/DannyMoped07/CIMG0476.jpg)
New Shock:
(http://i26.photobucket.com/albums/c143/DannyMoped07/CIMG0477.jpg)
Good looking dismantle right now :):
(http://i26.photobucket.com/albums/c143/DannyMoped07/CIMG0506.jpg)
(http://i26.photobucket.com/albums/c143/DannyMoped07/CIMG0509.jpg)
(http://i26.photobucket.com/albums/c143/DannyMoped07/CIMG0515.jpg)
ALL DONE!!!! She rides amazingly!!!!!
(http://i26.photobucket.com/albums/c143/DannyMoped07/GEDC0034.jpg)
(http://i26.photobucket.com/albums/c143/DannyMoped07/GEDC0035.jpg)
(http://i26.photobucket.com/albums/c143/DannyMoped07/GEDC0037.jpg)
(http://i26.photobucket.com/albums/c143/DannyMoped07/GEDC0038.jpg)
(http://i26.photobucket.com/albums/c143/DannyMoped07/GEDC0040.jpg)
VIDEOS:
#1:
http://www.youtube.com/watch?v=j1SpMSavvJA (http://www.youtube.com/watch?v=j1SpMSavvJA)
#2:
http://www.youtube.com/watch?v=nSoRue1Tvwc (http://www.youtube.com/watch?v=nSoRue1Tvwc)
#3: NEW ONE as of 3/17:
http://www.youtube.com/watch?v=O0fa6H83Kqk (http://www.youtube.com/watch?v=O0fa6H83Kqk)
That's all! At least now I have a place to post updates... lol.
Danny
Looking good! I love that chin spoiler.
THanks, more to come... as soon as I uploaded all my pics Photobucket went down for maintenance. Blah... lol.
Dan
HAHA, photobucket finally came back up and my 2nd video uploaded to youtube!!! Enjoy!
More progress happening today... hopefully getting everything wired up.
Dan
Hey there Danny,
Can you change the oil and filter with the chin fairing still on or do you have to remove it each time?
Thanks,
Trwhouse
Quote from: Trwhouse on February 05, 2009, 03:35:01 PM
Hey there Danny,
Can you change the oil and filter with the chin fairing still on or do you have to remove it each time?
Thanks,
Trwhouse
The chin spoiler actually doesn't inhibit changing oil at all. There is a good sized hole under the spoiler that you can't see to allow for not only the drain plug to drain with no problems, but when the filter door opens the oil drips right down into the pan missing the spoiler completely. Sure, it's a little tight getting a wrench in there.. but if you come up from the bottom with a 2 inch extension it's a piece of cake.
Dan
What chin spoiler is that? Is it from Powerbronze?
Quote from: Danny500 on February 05, 2009, 06:24:05 PM
Quote from: Trwhouse on February 05, 2009, 03:35:01 PM
Hey there Danny,
Can you change the oil and filter with the chin fairing still on or do you have to remove it each time?
Thanks,
Trwhouse
The chin spoiler actually doesn't inhibit changing oil at all. There is a good sized hole under the spoiler that you can't see to allow for not only the drain plug to drain with no problems, but when the filter door opens the oil drips right down into the pan missing the spoiler completely. Sure, it's a little tight getting a wrench in there.. but if you come up from the bottom with a 2 inch extension it's a piece of cake.
Dan
That's good to know. I have been hesitant to get a chin spoiler because I didn't want to make oil changes any more difficult, but if it stays out of the way.... Now you've gone and gotten me all ready to spend money again, grrr.
Quote from: 5thAve on February 05, 2009, 07:36:26 PM
What chin spoiler is that? Is it from Powerbronze?
Nope, it's a Metzler? or Mezler? I can't remember the actual name, but it's one of the original stock pieces that came as an option back in the 90's with the front cafe fairing. Someone just had this one kicking around on e-bay a while back WITH all the hardware, so I jumped on it.
There's a list or site roaming around here somewhere that has a whole sheet with all the different spoilers that fit the GS500, the one that I have is the first one on the list.
Dan
So I just spent the afternoon splicing wires and getting my dash ready for a re-install along with making piggy-backs for the rear directionals to meet up with the stock harness.
First I had to install a diode on the dashboard turn-signal indicator bulb. So off came the dash:
(http://i26.photobucket.com/albums/c143/DannyMoped07/CIMG0526.jpg)
Out came the lights:
(http://i26.photobucket.com/albums/c143/DannyMoped07/CIMG0529.jpg)
Separated the wires to the indicator bulb for blinkers:
(http://i26.photobucket.com/albums/c143/DannyMoped07/CIMG0531.jpg)
Following the directions. Chopped both wires off, spliced Red wire into leads (+ and - from harness), Blue wire onto HOT (Green) and LONG black wire onto original ground (Black):
(http://i26.photobucket.com/albums/c143/DannyMoped07/CIMG0540.jpg)
Taped everything back up like normal:
(http://i26.photobucket.com/albums/c143/DannyMoped07/CIMG0542.jpg)
Along with making extensions for rear blinkers I now have everything re-installed in the dash and ready to be put back on the bike. The only difference with the diode is the extra ground wire (with male plug end to go into existing non-used ground), and a little extra wiring hanging out the back of the gauge guard due to the diode and shrink connections (can't bend the wire anymore).
(http://i26.photobucket.com/albums/c143/DannyMoped07/CIMG0547.jpg)
(http://i26.photobucket.com/albums/c143/DannyMoped07/CIMG0550.jpg)
(http://i26.photobucket.com/albums/c143/DannyMoped07/CIMG0553.jpg)
So now, hopefully, my damn blinkers will work right! Lol.
Dan
So are you going for the Faired look? I like the headlight, but what kind of fairing are you gonna use? Chin spoiler rocks!
No fairing...
Going for something like this:
(http://www.1000rr.net/forums/attachment.php?attachmentid=19816&d=1203398976)
(http://www.1000rr.net/forums/attachment.php?attachmentid=19813&d=1203398913)
Dan
Quote from: Danny500 on February 05, 2009, 08:41:09 PM
Quote from: 5thAve on February 05, 2009, 07:36:26 PM
What chin spoiler is that? Is it from Powerbronze?
Nope, it's a Metzler? or Mezler? I can't remember the actual name, but it's one of the original stock pieces that came as an option back in the 90's with the front cafe fairing. Someone just had this one kicking around on e-bay a while back WITH all the hardware, so I jumped on it.
There's a list or site roaming around here somewhere that has a whole sheet with all the different spoilers that fit the GS500, the one that I have is the first one on the list.
Dan
Is it this one? http://www.whaccessories.com/GS500Accessories.htm
danny, those first virgin shots of the bike are pretty nice. think i'll remove my flyscreen this weekend because of your shots. like what you're doing with the F headlight, are those mirror signals functional ?
Quote from: fred on February 05, 2009, 11:47:14 PM
Is it this one? http://www.whaccessories.com/GS500Accessories.htm
That's the one Fred!!!! The fairing is the first one on the list... the GIMBEL Belly-Pan.
Quote from: ohgood on February 06, 2009, 04:20:54 AM
danny, those first virgin shots of the bike are pretty nice. think i'll remove my flyscreen this weekend because of your shots. like what you're doing with the F headlight, are those mirror signals functional ?
Why yes they are functional :). I actually got them all hooked up and WORKING last night thanks to the diode!!! I was pretty excited, not going to lie. Lol.
They look so much nicer than stock being about 1/2 the height off the bars and they're just a great shape too.
Yeah, fairings and windscreens gotta go on the E IMHO... I think the F is the best custom way to go because it gives you an area large enough to tuck all the wires up behind when it's installed.
Dan
Quote from: Danny500 on February 06, 2009, 07:24:26 AM
Quote from: fred on February 05, 2009, 11:47:14 PM
Is it this one? http://www.whaccessories.com/GS500Accessories.htm
That's the one Fred!!!! The fairing is the first one on the list... the GIMBEL Belly-Pan.
Quote from: ohgood on February 06, 2009, 04:20:54 AM
danny, those first virgin shots of the bike are pretty nice. think i'll remove my flyscreen this weekend because of your shots. like what you're doing with the F headlight, are those mirror signals functional ?
Cool! Thanks. I'm going to have to look into getting one...
Why yes they are functional :). I actually got them all hooked up and WORKING last night thanks to the diode!!! I was pretty excited, not going to lie. Lol.
They look so much nicer than stock being about 1/2 the height off the bars and they're just a great shape too.
Yeah, fairings and windscreens gotta go on the E IMHO... I think the F is the best custom way to go because it gives you an area large enough to tuck all the wires up behind when it's installed.
Dan
Nice looking bike!!! Where did you get the rear signals from?????
:cheers:
Quote from: springy14 on February 06, 2009, 11:12:40 AM
Nice looking bike!!! Where did you get the rear signals from?????
:cheers:
I believe they were from MotoSport.com, they are DMP's "Power Grid LED Marker Lights" . They're super nice... rubber mounted so they wont snap off like my old ones. They're also as bright as stock, which is awesome.
Dan
Good placement of the headlight :thumb:
On the diode why did you take it all apart like that? Mine was just a ten minute get the gauge panel up and splice to turn signal indicator. Just curious!
Mary
Quote from: Toogoofy317 on February 07, 2009, 02:18:14 AM
On the diode why did you take it all apart like that? Mine was just a ten minute get the gauge panel up and splice to turn signal indicator. Just curious!
Mary
Well, up here. It's between 5 and 10 degrees out and that's not fun in a non-heated barn. So, since I had the headlight off anyway, I just unscrewed the gauge buckets, unclipped the wires and went inside where it was nice and warm :)...
Dan
The beginning of the end of the headlight mods.
Chopped all the unusable tabs, trimmed the large ones, bondo'd from the first lip up and over the clips that connect the 'glass' to the bucket.
(http://i26.photobucket.com/albums/c143/DannyMoped07/CIMG0557.jpg)
(http://i26.photobucket.com/albums/c143/DannyMoped07/CIMG0559.jpg)
(http://i26.photobucket.com/albums/c143/DannyMoped07/CIMG0568.jpg)
(http://i26.photobucket.com/albums/c143/DannyMoped07/CIMG0581.jpg)
(http://i26.photobucket.com/albums/c143/DannyMoped07/CIMG0577.jpg)
OH.. and for the record.
I... HATE... BONDO.... Next time I think I'll try fiberglass... or just not ever have a next time again... lol.
Dan
Quote from: Danny500 on February 10, 2009, 12:01:41 AM
OH.. and for the record.
I... HATE... BONDO.... Next time I think I'll try fiberglass... or just not ever have a next time again... lol.
Dan
It does look good though, so it was probably worth it...
Quote from: Danny500 on February 09, 2009, 11:29:52 PM
The beginning of the end of the headlight mods.
Chopped all the unusable tabs, trimmed the large ones, bondo'd from the first lip up and over the clips that connect the 'glass' to the bucket.
(http://i26.photobucket.com/albums/c143/DannyMoped07/CIMG0557.jpg)
(http://i26.photobucket.com/albums/c143/DannyMoped07/CIMG0559.jpg)
(http://i26.photobucket.com/albums/c143/DannyMoped07/CIMG0568.jpg)
(http://i26.photobucket.com/albums/c143/DannyMoped07/CIMG0581.jpg)
(http://i26.photobucket.com/albums/c143/DannyMoped07/CIMG0577.jpg)
Good job mate! Looks nice! :thumb:
BTW I was considering doing the same, but with this headlight :icon_mrgreen:
(http://img99.imageshack.us/img99/8421/538453123mk9.jpg)
Quote from: CZOKO on February 10, 2009, 06:49:44 AM
BTW I was considering doing the same, but with this headlight :icon_mrgreen:
(http://img99.imageshack.us/img99/8421/538453123mk9.jpg)
I was actually gonna use a GSXR headlight, but then I found this F headlight really cheap. Do it up!
I'm planning on painting mine gloss black to match the rest of the bike and put a silver suzuki sticker on the top somewhere.... possibly a silver stripe going up the side of it to break up the black.
We'll see.
Thanks for the comments!
Dan we are almost doing the same thing with that headlight. I am doing the bondo as well, and yes it is a pain. I did however keep the top mount tab. When I was taking the fairing off it broke. So I cannibalized the top triangle piece. So my plan is to mount that back on the top and have it painted the same yellow as the bike. The other thing I am thinking of doing is wrapping the now bondo'd edge in carbon look vinyl rather than painting it.
Quote from: Grommett2k on February 10, 2009, 10:44:42 AM
Dan we are almost doing the same thing with that headlight. I am doing the bondo as well, and yes it is a pain. I did however keep the top mount tab. When I was taking the fairing off it broke. So I cannibalized the top triangle piece. So my plan is to mount that back on the top and have it painted the same yellow as the bike. The other thing I am thinking of doing is wrapping the now bondo'd edge in carbon look vinyl rather than painting it.
That's not a bad idea actually. I wish they made that vinyl in a shrink-wrap sort of material... like Easter egg wrappers... cuz every time I use that stuff it peels off within days.
Bud I'm doing a metallic flake gloss black for the headlight, so it matches the under-spoiler and the rest of the bike closely.. then i'm going to try and find a small, silver "S" or "SUZUKI" decal and stick it in the center of the "V" on top of the light... almost in the identical spot where the wind-screen has it.
Dan
Mock ups make me all excited...
(http://i26.photobucket.com/albums/c143/DannyMoped07/CIMG0590.jpg)
(http://i26.photobucket.com/albums/c143/DannyMoped07/CIMG0592.jpg)
(http://i26.photobucket.com/albums/c143/DannyMoped07/CIMG0595.jpg)
(http://i26.photobucket.com/albums/c143/DannyMoped07/CIMG0605.jpg)
(http://i26.photobucket.com/albums/c143/DannyMoped07/CIMG0609.jpg)
(http://i26.photobucket.com/albums/c143/DannyMoped07/CIMG0613.jpg)
Sweet...
Very cool! That headlight on the naked GS looks so evil, I love it!
Welps... did the carb work today. Got the 127.5's installed and cleaned it all up. Taking the time to clean where I can before re-installing everything. No pics yet, but soon.
If you've read my other posts I accidentally stripped the oil pan drain plug, so I turned a 40 dollar repair into a 400 dollar order from bike bandit... here's the order so far.
Throttle grip (stock one was destroyed by PO who installed (and GLUED and CUT THE HANDLEBARS to fit) heated grips... grrr.
Frame plug (broke it when trying to install after shock swap)
Oil Pan, Gasket, Bolt, and Washer
and...
Vance and Hines pipe... yay!!!
Also threw in 2 new crush gaskets for the exhaust, trying (fruitlessly) to remove the originals.. they're kind of a pain in the ass.
Pics up soon of all the upgrades, just giving a heads up :)
:cheers:
Just got allll my parts installed.
New oil pan, gasket, filter, cover gasket, bolt and washer. Ding.. done.
Fresh OEM air-filter and plugs. Ding.. done.
Vance and Hines installed!!!!!!
So I bolted everything up, threw in some fresh oil, slapped the carbs back on and threw on the tank.... Just to hear the exhaust.
HOLY FREAKING BA-JESUS!!!!!! This thing sounds AMAZING!!!!! :icon_twisted: It sounds like a pissed off muscle-car made a baby with a stock Harley 883. I was half-expecting it to sound like a pissed off 4 wheeler like the Jardine system, but nope... Amazing. I couldn't be happier! I still have to sync the carbs and check the air/fuel but other than that the bike is DONE!!!
Now, I've had the bike drained of oil, for 2 weeks, with no oil pan on it, no exhaust on it and no carbs on it... I did have the intakes plugged but that's about all the protection from a recent snow storm and -3 degree weather this passed week.
When everything was bolted on and I went to start it the temp out was 10 degrees. I choked it, had the fuel on PRI and it turned over on the 3rd crank 1st try!!!! I was amazed!
The bike MAY run a little rich, but that's ok, better than being lean... I'll do some chops after it gets nice out and I have the time to dial everything in.
But as for right now I am STOKED as to how easy an install this was and how nice it sounds!
2 Complaints:
1. Had to carve a little bit off the inner edge of my chin spoiler to make it clear the exhaust. Also, since the headers go to the right the left side looks a tad empty if you look down at the bike from the front.
2. The can sticks WAYYYY out. I mounted the rear tab to the back of the stock mount (like where the stock one was). But it's still kinda far out... I'll just have to be SUPER SUPER SUPER careful NEVER to drop it, cuz it'll scar up that pipe pretty well.. Meh, I'll live.
Sweet!!! :cheers:
Pics soon! Sorry, it's too damn cold out!
Certainly sounds cool. I can't wait for pics.
Looking good! Happy for you.
Danny, I like what you did with your mirrors, very nice, and your headlight makes your bike look like a black wasp. I agree mostly with you on fairings, but if I could lay my hands on a cafe headlight fairing like Anne's I'd jump on it in a New York second! Too bad it's no longer made. The reason escapes me. I think it's the best custom item ever offered for the 500E. :thumb:
You'll love the V&H pipes. I just got some too. It was easy to change, wasn't it? Curiously, and lucky for me, my exhaust gaskets were still in nice shape so I reused them. They also lifted right out, super easy. I looked them over, saw no damage, so I put them back in and installed the pipes. I put my new pipes on just like the instructions said except for that metal guard, or whatever the hell it is, function of which is unclear to me, that goes on the right hand sidestand bolt. What the hell is that thing for?? I left mine off since it's pretty clear we don't need it on our model, but the instructions say nothing about omitting it for E models and using it for F models.
Didn't change my carb jets either. The PO put a Cobra slip-on on the bike and probably re-jetted. I don't know for sure what jets are in it, but it takes 15 minutes and 8 miles to warm-up completely in 50-60 degree weather and it has almost linear power, so I seriously doubt it's running too lean. Thoughts?
Quote from: bill14224 on March 04, 2009, 04:05:49 PM
Danny, I like what you did with your mirrors, very nice, and your headlight makes your bike look like a black wasp. I agree mostly with you on fairings, but if I could lay my hands on a cafe headlight fairing like Anne's I'd jump on it in a New York second! Too bad it's no longer made. The reason escapes me. I think it's the best custom item ever offered for the 500E. :thumb:
You'll love the V&H pipes. I just got some too. It was easy to change, wasn't it? Curiously, and lucky for me, my exhaust gaskets were still in nice shape so I reused them. They also lifted right out, super easy. I looked them over, saw no damage, so I put them back in and installed the pipes. I put my new pipes on just like the instructions said except for that metal guard, or whatever the hell it is, function of which is unclear to me, that goes on the right hand sidestand bolt. What the hell is that thing for?? I left mine off since it's pretty clear we don't need it on our model, but the instructions say nothing about omitting it for E models and using it for F models.
Didn't change my carb jets either. The PO put a Cobra slip-on on the bike and probably re-jetted. I don't know for sure what jets are in it, but it takes 15 minutes and 8 miles to warm-up completely in 50-60 degree weather and it has almost linear power, so I seriously doubt it's running too lean. Thoughts?
I do like cafe-looking bikes, but I wanted to just update the look of mine... Kinda give it the Gladius look. I love the sound of my V&H already, INSANE, but not ear-piercing standing next to/behind it... so it should be fine to ride w/o earplugs.
It WAS really easy to change out! I also left my stock gaskets in, mainly because I couldn't get them out... but there was no damage to them so I figured why not, leave em'.
Something tells me if the PO had simply a Cobra slip-on on the bike he DIDN'T re-jet. Mainly because slip on pipes don't change the backpressure too much, only the noise restriction. Since the VH has the V shaped headers there is FAR less back pressure w/o that cross pipe, plus the diameter seems to be a hair wider.
I would recommend getting some new plugs, going for a LONG ride keeping the RPM's up high and then do some plug chops. The power
should be linear for the most part, but around 5k there should be a bit of a kick (powerband). Are you running any washers on your needles? Are your air/fuel screws exposed? If not on both cases try putting 2 #3 stainless washers on EACH needle (search the wiki, it's in there) and also pop the carbs off and ensure there is at least a 125 jet in there. I put a 127.5 in mine only because I don't mind running a tad rich.
Also, have you had the carbs synced at all? Uneven carbs could be causing the docile acceleration. :cheers:
OH!!! And that metal guard is NEEDED on our bikes otherwise the center stand will hit the pipe!!! The stock pipe had a little tab welded to it with a rubber bung in it that the center stand rested on when in the UP position. So, just check that out. It's a 2 second install. :icon_mrgreen:
Dan:
If I left the little metal guard on the bike my pipe wouldn't fit. The pipe clears the center stand by about 1/2 inch, but not with that guard in the way! No docile acceleration either. When I said linear I meant there's no flat spot in the midrange which is something lean jetted air-cooled bikes of the 80's are infamous for. It pulls redline in 4th and 9500 in 5th, and I have a 17-tooth front sprocket. Got it up to an indicated 111 today with the petcock on PRIME. It's the DIAPHRAGM. It was starving for fuel at full throttle! I picked up 6 mph just by putting the petcock on PRIME. :woohoo:
Haha! Nice! I just buttoned everything up today and took her for a ride! I didn't notice any power gain... it sure does sound nicer though. I got it up to 80... didn't want to do much more as it was getting cold, I was uncomfortable, and the roads were shitty... other than that it felt like it'd still hit 110...
I do notice the linear acceleration. No lag, no dead spot.. just power on demand. Love it!
NEW PICS POSTED IN 1ST POST!!!!! Bike is allllll done :)!
Nice work! :thumb:
3rd video isn't working...
edit: nm, it's working now
Quote from: tripleb on March 17, 2009, 08:14:52 PM
3rd video isn't working...
It was JUST uploaded, so it may need a few mins to finalize.
what did you use to cut the unwanted tabs off your F headlight?
Quote from: FreedomAlive on March 22, 2009, 10:25:31 AM
what did you use to cut the unwanted tabs off your F headlight?
A hack-saw and a dremel. Then went over all the rough stuff with a sanding barrel on the dremel and bondo'd over it.