Some time ago I started making my own solo seat cowl from fiberglass.
I took some pictures while I was doing that so I will paste few of them and add description of what I was doing or what I was trying to achieve,
Write-up sort of thing ;)
1. I started by cutting a pieces of cardboard and shaping it using scissors and tape
(http://i206.photobucket.com/albums/bb128/kmlkrk/Solo%20Seat%20Cowl%20-%20Project/IMAG0021.jpg)
(http://i206.photobucket.com/albums/bb128/kmlkrk/Solo%20Seat%20Cowl%20-%20Project/IMAG0022.jpg)
(http://i206.photobucket.com/albums/bb128/kmlkrk/Solo%20Seat%20Cowl%20-%20Project/IMAG0023.jpg)
(http://i206.photobucket.com/albums/bb128/kmlkrk/Solo%20Seat%20Cowl%20-%20Project/IMAG0027.jpg)
2. Here is the finished cardboard mold:
(http://i206.photobucket.com/albums/bb128/kmlkrk/Solo%20Seat%20Cowl%20-%20Project/IMAG0031.jpg)
3. Then I cut a fiberglass mat in the shape of the top part of the mold
(http://i206.photobucket.com/albums/bb128/kmlkrk/Solo%20Seat%20Cowl%20-%20Project/IMAG0035.jpg)
4. I mixed the resin with the hardener and spread it over the mat and after that I put the mat on the top of the mold
(http://i206.photobucket.com/albums/bb128/kmlkrk/Solo%20Seat%20Cowl%20-%20Project/IMAG0036.jpg)
5. Since the cardboard mold wasn't smooth and even I knew I had to do a lot of sanding so I put extra layers of fiberglass to fill the cavities/depressions and to make the whole cowl strong
(http://i206.photobucket.com/albums/bb128/kmlkrk/Solo%20Seat%20Cowl%20-%20Project/IMAG0040.jpg)
6. I sanded a little to start forming a shape I was going for and added even more fiberglass after that
(http://i206.photobucket.com/albums/bb128/kmlkrk/Solo%20Seat%20Cowl%20-%20Project/IMAG0042.jpg)
7. The shape is more or less OK so...
(http://i206.photobucket.com/albums/bb128/kmlkrk/Solo%20Seat%20Cowl%20-%20Project/IMAG0045.jpg)
8. ... I remove the cardboard mold from under the cowl and I spread a layer of FIBERGLASS body filer (short fiber - strong enough yet easy to work with)
(http://i206.photobucket.com/albums/bb128/kmlkrk/Solo%20Seat%20Cowl%20-%20Project/IMAG0047.jpg)
9. After that I spread more filer to the other side trying to fill the cavities and form better shape
(http://i206.photobucket.com/albums/bb128/kmlkrk/Solo%20Seat%20Cowl%20-%20Project/IMAG0048.jpg)
10. then I do some sanding
(http://i206.photobucket.com/albums/bb128/kmlkrk/Solo%20Seat%20Cowl%20-%20Project/IMAG0049.jpg)
11. and more filer and more sanding and the thing is starting to look quite OK
(http://i206.photobucket.com/albums/bb128/kmlkrk/Solo%20Seat%20Cowl%20-%20Project/IMAG0070.jpg)
12. one thing that took me quite a while were the sides - I wanted to make them look like they belong to the bike and my cardboard mold did do the trick. I had to drill small holes in the cowl (on each side) and form a nice arches using the filer, so that the cowl is fitted nicely on the seat and on the side fairings
here is what it looked like before making the arches with filer:
(http://i206.photobucket.com/albums/bb128/kmlkrk/Solo%20Seat%20Cowl%20-%20Project/IMAG0052.jpg)
and here is after that procedure: (as you can see the arch is much longer, has better shape, and looks much better in my opinion)
(http://i206.photobucket.com/albums/bb128/kmlkrk/Solo%20Seat%20Cowl%20-%20Project/IMAG0053.jpg)
13. Here is the fitment on the seat (I believe I worked it even better later on but don't have picture)
(http://i206.photobucket.com/albums/bb128/kmlkrk/Solo%20Seat%20Cowl%20-%20Project/IMAG0071.jpg)
14. and here are two shots after final sanding
(http://i206.photobucket.com/albums/bb128/kmlkrk/Solo%20Seat%20Cowl%20-%20Project/IMAG0073.jpg)
(http://i206.photobucket.com/albums/bb128/kmlkrk/Solo%20Seat%20Cowl%20-%20Project/IMAG0075.jpg)
That is it for now. The cowl is ready for primer and paint, but I have to wait 3 weeks until my friend comes back from the vacation, as he will get me the primer and the paint - he works in car body shop, so he can get me that stuff much cheaper than ColorRite.com.
Total cost so far is: $35 and that includes:
$20 fiberglass mat and resin
$15 fiberglass body filler
paint brush (to spread resin) - FREE - leftover from painting the house
gloves - FREE - same as above
sandpaper - FREE - dad works at auto body shop
other tools - FREE - same as above :thumb:
I just would like to add that I had no previous experience in working with fiberglass, fillers or anything related so this was the first time for me.
I had a great time and have learned a lot.
My only advice to those who would like to do something similar and have no experience in body work: make sure you have TONS of free time before you start!
If you read everything I wrote and feel exhausted just imagine that I had to WRITE all of that ;) haha
cheers and good luck with your own projects!
KML
Look great!
I'm really impressed by all the things you guys can make from fiberglass. It's something I've never messed with. It's definitely on my list of things to do someday, but I've got too many other projects I want to work on in the mean time, not to mention I HATE sanding. It took me all winter to finish the walls in my basement because I couldn't bring myself to sand the compound down so I could paint them.
I'd love to see a picture of your whole bike with the cowl on, even if it's unpainted.
I own that same hammer that's on the top right corner of your tool board!
:star: :star: :star: very cool!
Look forward to seeing it painted.
that is sweet, I might give that a try one day . love to see the finished product.
wow sweet job man!
how are you going to keep the cowl in place? are you adding a screw somewhere? did i miss something? :dunno_white:
i think i'm inspired to give this a try.
cheers,
~drin
looks really good. :thumb: awesome job.
thanks for the write up and the pics.. i dont have the time yet.. but it is very tempting. I am sure you are just making it look easy. Did you use mechanical sander? or is this all by Hand. Is there a specific sand paper you started out with and ended? 180 at the beggining then 300 for final?
Sick.
First of all thanks very much for kind words!!!
Quote from: Bluehaze on June 20, 2009, 08:34:54 AM
[...] Did you use mechanical sander? or is this all by Hand. Is there a specific sand paper you started out with and ended? 180 at the beggining then 300 for final?
All done by hand. Have pneumatic sander laying on the shelf, but no compressor in the garage :icon_neutral:
I have no clue what sand paper I used... I did not look at the numbers ;) I just touched it and figured that it was going to work well.
I would assume this was something in the range of 120-180.
I will be using finer sand paper after the cowl is covered with primer to make it as smooth as possible.
Quote from: drincruz on June 20, 2009, 07:29:37 AM
wow sweet job man!
how are you going to keep the cowl in place? are you adding a screw somewhere? did i miss something? :dunno_white:
i think i'm inspired to give this a try.
cheers,
~drin
you did not miss anything. I did not explain yet. The plan is to make a "lip" kind of thing on the inner part of the the cowl.
I would slide the seat in the lip and use 1 or 2 screws to keep it secure and to prevent it from shifting around.
there would also be 2 smaller lips or aluminum angles located on the inner side but towards the front (closer to the tank) that would prevent the cowl from lifting upwards.
there goal is to make the cowl attached from underneath so there are no screws visible anywhere O0
well, it's only a plan for now :thumb: I have three weeks to figure that out.
And for those who think it's difficult to make: it really isn't that hard, it is just time consuming and sometimes a bit tedious.
If I were to do one more from scratch I would probably spend more time preparing the mold, and then I'd use more body filer and then sand to create perfect shape, instead of sanding after each layer of body filer.
Quote from: tt_four on June 19, 2009, 11:48:38 PM
[...]
I'd love to see a picture of your whole bike with the cowl on, even if it's unpainted.
[...]
here is the only picture of the whole bike with cowl I have:
(http://i206.photobucket.com/albums/bb128/kmlkrk/Solo%20Seat%20Cowl%20-%20Project/IMAG0074.jpg)
Missed this over the weekend. Actually wasn't allowed near a computer, lol. Gotta love holidays.
This is quite nice work! I really like the step by step that you provided. Almost looks easy but I am sure it takes some time and patience. I cannot wait to see it painted up.
I might have missed it, but how is it going to mount? I bet I read it and forgot, lol.
Jon
^^^^^^
I explained how I am going to mount it in my previous post :thumb:
I was thinking of doing this if I went with a stock tail but Im getting the mmotos full kit so, Idecided against it, However, I was going to mount mine with two screws on the front by your arse, then drill and tap a hole in the grab handle dead center and use a third on top, to go into that hole.
Looks fantastic! Great job!
annguyen - thanks very much, I spent many hours working on that cowl.
Chanse - using 3 screws is not a bad idea and I though about that - it is sort of easy and quick solution,
BUT I want to make the mounting invisible :thumb:
I probably will be working on it tomorrow so I will let you know if I can do it or not.
cheers
looks great! I think you'll be happy with the final look. When I made my tail I added a lip that wraped under the seat so it went between the seat and the tail piece which then held it in place. I wasn't to worried about making it removeable so as long as its on and stays then I'm happy!
Looks great! Wish i had the time.
ya know If your gonna make a lip to slip under the seat all you would need is the one screw on the grab bar like I said, that would make it quick to take on and off and you could put the screw in your pocket. and maybe make a mount or something to store the cowl if your on the run. I was kinda thinking of making a different profile that would double as an undertail, Havent quite figured it all out yet but I know youd have to remove the factory undertail fender. Just a thought as of right now...
Quote from: utgunslinger13 on June 22, 2009, 07:08:13 PM
looks great! I think you'll be happy with the final look. When I made my tail I added a lip that wraped under the seat so it went between the seat and the tail piece which then held it in place. I wasn't to worried about making it removeable so as long as its on and stays then I'm happy!
Mine doesn't have to be easily removable either. I never ride with a passenger, so I doubt I will have to take it off.
But if I have to, it will probably be only 2 screws :thumb:
Quote from: Chanse on June 22, 2009, 07:58:07 PM
[...]I was kinda thinking of making a different profile that would double as an undertail [...]
I say go for it! it would surely look interesting!
If you don't have much free time, you can spread the work over few weekends, and work on it whenever the weather sucks :thumb:
a small update:
I made the mounting for the cowl. It went easier than I thought :thumb:
I ended up using exactly ZERO screws and I am very happy with that. The cowl can be put on and off any time anywhere without using any tools.
Here are some pictures from the process:
1. after first layer of fiberglass
(http://i206.photobucket.com/albums/bb128/kmlkrk/Solo%20Seat%20Cowl%20-%20Project/IMAG0083.jpg)
2. trimmed a little to create desired shape
(http://i206.photobucket.com/albums/bb128/kmlkrk/Solo%20Seat%20Cowl%20-%20Project/IMAG0084.jpg)
3. and finally, after bit if sanding and second layer of fiberglass, is the finished mounting system with the seat inside.
(http://i206.photobucket.com/albums/bb128/kmlkrk/Solo%20Seat%20Cowl%20-%20Project/IMAG0086.jpg)
cheers
very nice! do those tabs stop it from sliding backwards as well as forwards?
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.
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... :icon_sad:
I will redo them both tomorrow
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.
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 :thumb:
unless the tab breaks again.
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
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
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.
thanks for ideas Chanse, but I already figured something else :thumb:
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
(http://i206.photobucket.com/albums/bb128/kmlkrk/Solo%20Seat%20Cowl%20-%20Project/IMAG0087.jpg)
2. close up on the nut and bolt
(http://i206.photobucket.com/albums/bb128/kmlkrk/Solo%20Seat%20Cowl%20-%20Project/IMAG0088.jpg)
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
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 "....
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 :thumb:
I told you in your thread that you inspired me and that I was going to make my own. I never lie ;)
cheers
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.
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 :thumb:
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 :cheers:)
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... :D
(http://i206.photobucket.com/albums/bb128/kmlkrk/Solo%20Seat%20Cowl%20-%20Project/IMG_20110402_144810.jpg)
(http://i206.photobucket.com/albums/bb128/kmlkrk/Solo%20Seat%20Cowl%20-%20Project/IMG_20110402_144826.jpg)
(http://i206.photobucket.com/albums/bb128/kmlkrk/Solo%20Seat%20Cowl%20-%20Project/IMG_20110402_144837.jpg)
(http://i206.photobucket.com/albums/bb128/kmlkrk/Solo%20Seat%20Cowl%20-%20Project/IMG_20110402_144903.jpg)
(http://i206.photobucket.com/albums/bb128/kmlkrk/Solo%20Seat%20Cowl%20-%20Project/IMG_20110402_144935.jpg)
(http://i206.photobucket.com/albums/bb128/kmlkrk/Solo%20Seat%20Cowl%20-%20Project/IMG_20110402_144950.jpg)
looks incredible!!!
hope the final product of my cowltech looks half as good as yours does
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!
new summer project :thumb:
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
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!
Looks good.
Is that about a 10 HP increase?
Cant wait to see the finished product man! you may have just inspired me (us)!!! O0 :thumb:
Great job! :thumb:
Looks good. Maybe someday I'll gain the patience to do something like this
Quote from: SoGone12 on April 05, 2011, 10:00:02 AM
Cant wait to see the finished product man! you may have just inspired me (us)!!! O0 :thumb:
hmmm... I thought it was finished ;)
What am I missing? Are you talking about the decals that I said I may have put on some day?
Quote from: ver4 on April 05, 2011, 09:18:08 AM
Is that about a 10 HP increase?
No irony necessary.
And NO it does NOT add extra 10, 20 or 100HP.
In fact it doesn't do anything.
It just lays there, kind of like an art.
It's there for you to look at and admire or hate.
But if you really want to find a use for it I guess you could consider it a extra storage space, or a back rest, or a backpack rest.
Quote from: Yev on April 05, 2011, 07:25:07 PM
Great job! :thumb:
Thanks
Quote from: BadgerBiker on April 05, 2011, 08:30:50 PM
Looks good. Maybe someday I'll gain the patience to do something like this
thanks.
My advice: make a super precise mold. You will be able to get away with 1 or 2 layers of fiberglass and minimal amount of sanding.
:oHave you ever thought about pulling a mold off the one you made and selling it to the rest of us??????????
Quote from: ghostrider_23 on April 06, 2011, 12:26:04 PM
:oHave you ever thought about pulling a mold off the one you made and selling it to the rest of us??????????
I did :D
the only problem is that I absolutely have no time to do it right now. I take 5 classes, work 35hrs/week and also have a freelance project to take care of.
Also if I sell the mold/cowl my cowl will no longer be unique/one of a kind :dunno_white:
Awesome!! That's the best one yet. Only criticism I would offer for if anyone was to do there own, and maybe it's different in person, is I think it would look better with some sort of contour lines along the top.
Do the hand guards interfere at all with turning the bars to full lock? I tried to use another kind and had all kinds of problems. But also I don't have stock bars.
Quote from: GI_JO_NATHAN on May 02, 2011, 07:00:48 AM
Awesome!! That's the best one yet. Only criticism I would offer for if anyone was to do there own, and maybe it's different in person, is I think it would look better with some sort of contour lines along the top.
Do the hand guards interfere at all with turning the bars to full lock? I tried to use another kind and had all kinds of problems. But also I don't have stock bars.
Thanks for kind words! Part of the credit goes to the guy I took the idea from :thumb: (I forgot his username...)
1. I agree that it would look better with some kind of contours/decals, but I am not very artsy so it's hard for me to come up with something.
If you have any idea or sketch let me know please!
2. Hand guards slightly touch the mirror, but I don't have any issues with full lock.
Quote from: kml.krk on April 06, 2011, 05:06:52 PM
Quote from: ghostrider_23 on April 06, 2011, 12:26:04 PM
:oHave you ever thought about pulling a mold off the one you made and selling it to the rest of us??????????
I did :D
the only problem is that I absolutely have no time to do it right now. I take 5 classes, work 35hrs/week and also have a freelance project to take care of.
Also if I sell the mold/cowl my cowl will no longer be unique/one of a kind :dunno_white:
but think of the extra cheddar you can make while helping out the community. its not like there is a HUGE number of us anyways.
Your bike makes me love my yellow 04 so much more. I got it like 2 week ago and i'm planning on painting it white or buying black fairings. I might just keep it yellow now.
^^^
yellow is the most visible of all colors = increased safety and visibility.
not even red is as visible as yellow.
I would never paint my bike black.
First thing safety, than pretty ;)
Quote from: kml.krk on May 09, 2011, 11:39:13 AM
^^^
yellow is the most visible of all colors = increased safety and visibility.
not even red is as visible as yellow.
I would never paint my bike black.
First thing safety, than pretty ;)
Years ago, crash data (at the time) showed Red cars were involved in more accidents than any other color.
In Aust, motorcyclists wearing White helmets have fewer crashes with other cars - maybe cause it makes the cars pause just a bit cause Motorcycle Cops wear white helmets or riders who prefer white helmets ride differently :dunno_black:
I prefer my ninja stealth black with black helmet and black jacket :thumb:
If cars can not see large red fire engines with sirens wailing and lights flashing, nor whitish colored ambulances with sirens wailing and lights flashing, nor white motorcycles with flashing lights right in front of them, as seen in this video http://www.youtube.com/watch?v=ynXnGcOn4Uc then my small visual footprint has no hope no matter what color bike or clothing.
I've had people look right at me, make eye contact and Still act as if you did not exist causing you to take evasive. If riding on a higher visible color and wearing higher visible gear makes You comfortable, then do it, but don't expect it to do anything, take avoidance matters into your own hands, and you should be right. (Don't just rely on your apparent high viz to save you.)
Michael
Quote from: kml.krk on May 09, 2011, 11:39:13 AM
^^^
yellow is the most visible of all colors = increased safety and visibility.
not even red is as visible as yellow.
I would never paint my bike black.
First thing safety, than pretty ;)
while you can be the safest person in the world. It takes 2 people to get into accidents. Only true safe thing to do is not be on the road and even then you have possible drunk drivers hitting you while walking.
Yellow is a bright color and should help maybe 1%, yes 1% makes a difference.
I finished it ;)
I decided not to put any ugly stickers on it. It will stay solid yellow, but I added a black molding to the edge.
It is more to protect the paint than for looks but I kind of like it.
(http://i206.photobucket.com/albums/bb128/kmlkrk/IMG_20110614_182017-1.jpg)
If you are wondering, yes the paint underneath is already destroyed... vibrations + sharp edge = eaten paint :dunno_white:
That's OK with me though, not planning to remove the cowl ;)
you should take the GS500 stickers off the back and put ones on the side of the cover.
I wanted to do that, but after looking up prices I decided I don't care that much...
or grab some vinyl and do a arrow from the corners of the front to the tip of the cowl and make it black and silver like the tank paint... also... MAKE ME ONE!
Quote from: crzydood17 on June 28, 2011, 02:56:29 PM
or grab some vinyl and do a arrow from the corners of the front to the tip of the cowl and make it black and silver like the tank paint... also... MAKE ME ONE!
that would be quite opposite to what I said about leaving it solid yellow... ;)