Having ridden the GS, daily since picking Feb, we came to a few conclusions. :nono: :icon_idea:
The handlebars were just way too high for me, I had the urge, to just bury my head in dial faces, become more, as one, with not only my gorgeous other half, Deb, but our metal horse.
We both felt a fairing/ belly pan would be a worthwhile addition.
Few of the maintantance tasks are due, along with paint added has come off etc.
What actually was a mis under standing, on my part, led to a cure (For one area) I for one am grateful for. :woohoo:
"Clip ons" is a new term to me.......and I just blew the budget (figuratively) on the different options, of engineered treasures.
So, the net i searched, for a breaker who could supply me with the goods I craved for.
And what came, in the post?
Exactly the same as the parts already fitted. :D
But, hey, while theres Blu Tack, Cello Tape, and all manner of like substances, I figure what the hell.
The bars are certainly lower, and the difference has been worthwhile, for us.
Although, we need to modify more, the cables, leads seem fine, only repercussion has been headlight flashed/flashes when changing gear. As far as we know, it did'nt happen before. So, will start with controls.
The normal process for fabricating a GRP item, for us has been, usually, plug, mold, then article.
On a few articles we have gone straight to mold or other "cheats".
But as were using CF, figure its worth trying to sculpt form, then laying up over that.
We've purchased a screen, just need to source suitable fixings.
The seat we would like to re do, CF, two patches of seating.
Will most probably find few other jobs, such as cover tank, panels etc.
Any assistance in design of fairing, belly pan, etc greatly appreciated.
Done some searching, basic principles seem straight forward ( Not that means we'll do an appropriate job ;) but figure, ask, in case theres any definitive sources. :technical:
:cheers:
(http://i114.photobucket.com/albums/n244/ukcjm/DSC04201.jpg)
With the bars set in a way were comfortable with,
preparation for the carbon fibre fairing has led to the sourcing of various goodies.
Plugs/ forms, we like to fabricate using as much rubbish as possible. Important thing to us is that its relatively stable, for suitable amount of time, and keeps its shape whilst being layed up.
The shaping usually is finished with sanding Upol, or similar.
(http://i114.photobucket.com/albums/n244/ukcjm/SuzukiGSXR750K62006standardscreen.jpg)
Screen is
Suzuki GSXR750 K6 2006 standard screen.
Nice shape, looks easy to take an imprint from, using filler or fibreglass, cellotape etc.
We have some various sized threaded rivets, that may be suitable for screen, although, look highly likely for other fixings.
Either way, flush fitting all round as much as possible.
(http://i114.photobucket.com/albums/n244/ukcjm/bikinifairing.jpg)
Lights we wish to adapt from above, not sure about the indicators yet. Seen some great after market ones, but might just incorparate originals, or look more closely at various options.
Rear will just all be blended in, nothing too elaborate.
Few bits need tidying, but figure those as we progress.
Loads more to take into account, but basics at least off the ground.
Whole bike will be stripped into components. Have some paint left from previous projects, so looking forward to the tasks ahead.
:woohoo:
(http://i114.photobucket.com/albums/n244/ukcjm/GSSeatForm11.jpg)
Basic start of seat.
Decided, that for us, this was best place to start for accumulated panels etc.
(http://i114.photobucket.com/albums/n244/ukcjm/GSSeatForm1.jpg)
Wish to experiment a little with shaping, so have cut open old saddle, and will see how seat feels.
(http://i114.photobucket.com/albums/n244/ukcjm/DSC04276719x350.jpg)
Two days without riding has left us like grizzlys with a toothache.
Fibreglass piece was cut further, placed, sat on.....felt better turned backward....then tossed for now.
Could search fleabay for funky rear light, but if theres cash spare, its going elsewhere.
Headlight unit came in post today, and looks good at this point, to add the indicators at rear.
I must say I have NEVER seen a GS500 with the clipons mounted upside-side-down like that...
(http://i114.photobucket.com/albums/n244/ukcjm/DSC04322408x429.jpg)
Hand layed up two layers of CF, using polyester resin. GTT not that high, although will make little difference as most will be sanded away.
Epoxy resin outside section, holes started for rear light, although when epoxied together will be enlarged. Maybe use lenses found on google search.
Next steps will be, to allow for covering on side runners, front seat.
Decide on shaping, fabricate, and set as low as possible.
Copy side panels.
Quote from: ChrisAndDeb. on April 14, 2011, 10:53:07 AM
(http://i114.photobucket.com/albums/n244/ukcjm/DSC04276719x350.jpg)
So this will be the permanent seat thing? I see you've now covered your battery entirely. So if you need to change it or charge it, what, you need to unbolt and unseal everything?
Michael
Quote from: mister on April 16, 2011, 11:57:03 AM
Quote from: ChrisAndDeb. on April 14, 2011, 10:53:07 AM
So this will be the permanent seat thing? I see you've now covered your battery entirely. So if you need to change it or charge it, what, you need to unbolt and unseal everything?
Michael
Greetings.
Nope, the pic you've re-posted, is part of "Form or pattern." CF was layed up over, and gave us a glorified bracket/ article to work with.
No real established method decided, on fixing CF seat, although as the plastic guard under neath is due to go as well, maybe oppotunity of using original catch.
:cheers:
Incidentally, we have normally found, that fixing points generally lead the way for re designed articles.
So, a break from norm in alot of ways.
Also, we were going to re do rear tyre guard, while fabricating form. Thought that maybe wrapping the tyre/wheel, in rope , layer of resin, filler to finish, then laying CF. Decided to wait till we strip the GS.
The only way forward on designing the fairing, seems to be to attempt a DIY wind test. By that, we mean setting up blowers, directing approx' 30mph air at front, with smoke pellets, and see if anything can be evaluated.
We did a similar test before, although on car, so it will not take into account vortices etc, but apparently cotton wool helps there......maybe a positive start.
(http://i114.photobucket.com/albums/n244/ukcjm/GSSidefg1768x315.jpg)
Side panels were given three coats of release wax, although damage to the originals seems inevitable without using further protection.
Corners, not worried about, hence did not use chopped strand.
One layer of Gel coat though, due to stab-ability factor.
One layer of 600 fibreglass, split first.
(http://i114.photobucket.com/albums/n244/ukcjm/seatpieceonbikefromtank576x538.jpg)
Seating section seems nicely placed, with convenient opening for front/seat hook.
Additionally sides look low, although still not happy about height.
Quote from: ChrisAndDeb.The only way forward on designing the fairing, seems to be to attempt a DIY wind test. By that, we mean setting up blowers, directing approx' 30mph air at front, with smoke pellets, and see if anything can be evaluated.
We did a similar test before, although on car, so it will not take into account vortices etc, but apparently cotton wool helps there......maybe a positive start.
You may find this article series interesting/helpful.
Part 1Part 2Part 3Part 4Part 5
Quote from: pave_spectre on April 19, 2011, 12:46:31 AM
You may find this article series interesting/helpful.
Part 1 (http://www.autospeed.com/A_108656/cms/article.html)
Part 2 (http://www.autospeed.com/A_108674/cms/article.html)
Part 3 (http://www.autospeed.com/A_108675/cms/article.html)
Part 4 (http://www.autospeed.com/cms/A_108676/article.html)
Part 5 (http://www.autospeed.com/cms/A_108677/article.html)
:thumb:
We are very grateful. Many thanks.
The idea of filming/ photos was suggested, but impossible at the time, due to no engine, gearbox, running gear.......
Still is.
Took a year to fabricate roof plug, averaging 2 hours a day. Big decider was side vents, and allowing flow to a rear mounted, auxiliary, radiator:
(Apologies in advance.....Not for purists)
(http://i114.photobucket.com/albums/n244/ukcjm/PICT0874187x97.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/PICT3134211x158.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/BLOGGER1-1211x99.jpg)
Seeing the linked Aero testing really does add considerably.
At the time we also searched DIY wind test/ tunnel etc, found some interesting PDF's (Might be accessible, will look later)
Will forward links, if thats ok.
:cheers:
Adding wool tufts to the DIY sections we wish to fabricate does seem even more appealing now.
(http://i114.photobucket.com/albums/n244/ukcjm/DSC04396723x482.jpg)
Side panels released.
Will most probably be scrapped at end of day, but can now start blending everything in.
Managed to get to the lay up while green, and trimmed with carpet blade.
(http://i114.photobucket.com/albums/n244/ukcjm/DSC04410768x576.jpg)
Headlight unit has small amount of damage, nothing to get in a sweat about.
Originally was thinking of single unit, but went for twin, seemed compact enough etc.
Bid on Honda RVF400R NC35 headlights, at max' of £8, lost to 9+.
Had this item on watch, and secured with £10, 5 p&p.
(http://i114.photobucket.com/albums/n244/ukcjm/DSC04418555x461.jpg)
Possible final shaping options all seem "effective".
Going along the lines of a more "sculptured" look to blending in indicators, at the moment.
The headlight seems to fit in quite well behind screen that is supplied.
The shaping would help all round maybe.
So have sent mails to request price for replacement clear screen to mount headlights behind, in fairing.
(http://i13.photobucket.com/albums/a255/ahuacate/Smilies/eatpopcorn.gif)
(http://i114.photobucket.com/albums/n244/ukcjm/GSrearsideventscut1502x415.jpg)
Hopefully all aspects catered for, in location of rear vents.
As this point, see vent sides being as steep, as the around "four degree grip", area will allow.
Using cut outs as inner/lower, blend.
Thoughts of muliti mold or water matrix to play with shaping, passed quite quickly.
Keep it simple.
An addition for car mentioned previously, included bucket seat, which sees plug around half way through, for base.
During fabrication a section was layed up/ cut, to help measure symmetry.
Reclaimed from trash, stored, and tracked, this fits better all round, so needs to be duplicated.
Need to have half a day, to loose fit, things back in, explore variations, set some lines, etc.
(http://i114.photobucket.com/albums/n244/ukcjm/settingrearventdephGS1296x223.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/settingrearventdephGS436x293.jpg)
Re positioned/mounted some of electrics.
Will tidy up and finish when bike is stripped.
Used threaded rivets for hooks.
(http://i114.photobucket.com/albums/n244/ukcjm/settingrearventdephGS2598x381.jpg)
Made rear vents slightly longer.
The mock up fibreglass panels were layed up with around, 150 grams of Gel coat, 500 of resin, one and a half layers of 600, before trimming, but still maintained pretty good strength, despite each end having a generous amount of filler, to attach mountings and vent path cut.
(http://i114.photobucket.com/albums/n244/ukcjm/GSrearventfloor768x346.jpg)
Sides/ Top & bottom, filled, cut floor/ inner, to add cut section.
Couldn't source clear screen, but had BMW K1200s headlight protector on option list, which came today.
Boy loses gun......
Boy finds bigger gun.....
(http://i13.photobucket.com/albums/a255/ahuacate/Smilies/eatpopcorn.gif)
Quote from: mister on April 28, 2011, 01:28:05 PM
(http://i13.photobucket.com/albums/a255/ahuacate/Smilies/eatpopcorn.gif)
X2
Oh man, some serious work going on here! I checked out this thread when you first started it but was at work so I couldn't see any pictures or anything, so I figured I'd come back to it later. Forgot about it until now! I'll be sure to check it all out later!
:cheers:
(http://i114.photobucket.com/albums/n244/ukcjm/GSSamuriswish764x274.jpg)
Paper, chisel and liquid filler, paves the way......
(http://i114.photobucket.com/albums/n244/ukcjm/GSSamuriswish1767x309.jpg)
.......for The Samuri swish.
Once opposite side is same, can blend the fronts and rears, attach to bike, run and finialise.
How much harder is it to lay carbon fiber over fiber glass? It seems like it's pretty much the same process, no? Do you order it online or is there a good place to buy it?
Quote from: tt_four on April 29, 2011, 01:27:14 PM
How much harder is it to lay carbon fiber over fiber glass? It seems like it's pretty much the same process, no? Do you order it online or is there a good place to buy it?
Depends on weight, size of part, type of fabric weave. Fibreglass pretty much just has one common weave (not counting chopped strand), Carbon fibre comes in Plain, Twill, Unidirectional, and a few others.
Broadly speaking it is the same process as Fibreglass. I have been doing a little playing around with carbin fibre myself, mostly just working with small samples to try and get technique right.
https://www.fibreglast.com/ sell fibreglass, carbon, kevlar and pretty much all the tools you will need. Don't know how they compare price wise to other places, but one of the only ones I could find that ship to Oz.
Soon to be up dated. :icon_twisted: :thumb: :cheers:
Quote from: ChrisAndDeb. on April 11, 2011, 02:31:29 AM
(http://i114.photobucket.com/albums/n244/ukcjm/bikinifairing.jpg)
what is that headlight assembly from?
HAD the same exact thing on mine when I bought it but it was half broken and pretty much all junk except for the lights and housing.
looked pretty good and wouldnt mind considering getting it replaced.
(edit)
yep thats the exact same thing, just looked at some old photos.
heres how it was when i got it
(http://i19.photobucket.com/albums/b165/Chronno1201/014.jpg)
ugh and it figures!
asked and looked around for awhile after I first got the bike and came up empty.
and now that I'm pretty sure I tossed it in the trash emptying my trunk out, I find someone who probably knows what its from.
(http://i114.photobucket.com/albums/n244/ukcjm/GSTwinsUpdate-1.jpg)
Continued to equalise sides.
(http://i114.photobucket.com/albums/n244/ukcjm/GSTwinsUpdate1-2.jpg)
Cut off around 3mm from edges.
(http://i114.photobucket.com/albums/n244/ukcjm/GSTwinsUpdate2-1.jpg)
Rounded.
(http://i114.photobucket.com/albums/n244/ukcjm/GSTwinsUpdate3-1.jpg)
Placed on GS. Filled in gaps with all sorts of junk.
(http://i114.photobucket.com/albums/n244/ukcjm/GSTwinsUpdate4-1.jpg)
Filled with fibreglass and filler.
(http://i114.photobucket.com/albums/n244/ukcjm/GSTwinsUpdate5-1.jpg)
Slight shift in position.
(http://i114.photobucket.com/albums/n244/ukcjm/GSTwinsUpdate6-1.jpg)
Filled to tank line. Choose line, cut down to gelcoat.
(http://i114.photobucket.com/albums/n244/ukcjm/GSTwinsUpdate7-1.jpg)
Blended some lines.
(http://i114.photobucket.com/albums/n244/ukcjm/GSTwinsUpdate8-1.jpg)
Ok for now. Few waves here and there that need attention. Will need to re place on GS and finish.
(http://i114.photobucket.com/albums/n244/ukcjm/GSTwinsUpdate9.jpg)
Needed impression of inside of (Predator ? Has another name...? Will add to list.)
(http://i114.photobucket.com/albums/n244/ukcjm/GSTwinsUpdate10-1.jpg)
Taped edges of the magic weave to avoid pulling on strands etc.
(http://i114.photobucket.com/albums/n244/ukcjm/GSTwinsUpdate11-1.jpg)
Added another layer, left over night.
(http://i114.photobucket.com/albums/n244/ukcjm/GSTwinsUpdate12-1.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/GSTwinsUpdate13-2.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/GSTwinsUpdate14-2.jpg)
Bought CF braiding.
(http://i114.photobucket.com/albums/n244/ukcjm/GSTwinsUpdate15-2.jpg)
Boxed in light/bulb section etc.
(http://i114.photobucket.com/albums/n244/ukcjm/GSTwinsUpdate16-1.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/GSTwinsUpdate17-1.jpg)
Found couple of Lucas covers. Made template with saucepan lid, sealant and silver foil to take impression with fibreglass.
Used FG re enforcing foam to continue inner "Nose".
(http://i114.photobucket.com/albums/n244/ukcjm/GSTwinsUpdate18-2.jpg)
Used "Yatching" fibreglass to help blend lines.
(http://i114.photobucket.com/albums/n244/ukcjm/GSTwinsUpdate19-1.jpg)
Added CF inserts.
(http://i114.photobucket.com/albums/n244/ukcjm/GSTwinsUpdate20.jpg)
Blended bottom line with polyester resin, colour added.
(http://i114.photobucket.com/albums/n244/ukcjm/GSTwinsUpdate21.jpg)
Took FG impression of outside of after market fairing.
Set up laminated surface on thick board to house fairing screen etc.
(http://i114.photobucket.com/albums/n244/ukcjm/GSTwinsUpdate22.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/GSTwinsUpdate23.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/GSTwinsUpdate24.jpg)
Heated BMW light protector, bent round light housing, took impression of inside.
Laying up over these forms, will mean sunny side down.
Might have to jig saw puzzle some sections. Edges need testing.
Mold, CF and bagging does take the stress away.
Bought some Kevlar strip.
Started belly pan section.
all this custom work makes my head spin! keep up the good work, definitely can't wait to see this all shined up
(http://i114.photobucket.com/albums/n244/ukcjm/PICT4407.jpg)
Had to replace tyre, after a particularly bad bit of breaking.... :cookoo:
(http://i114.photobucket.com/albums/n244/ukcjm/PICT4563.jpg)
Took impression when fitted to bike, very kindly, and quickly by Kellaway motorcycles. Turned up, and they fitted me straight in, didn't even stratch the fresh layer of spray. :cheers:
Used one layer of CF.
Used to using Sicomin from suppliers in Bristol, but at this time using SP106.
http://www.mcmc-uk.com/products-epoxy.html
(http://i114.photobucket.com/albums/n244/ukcjm/PICT4599.jpg)
Took impression of circuar stainless bin, around 10 - 12 inches dia'.
Had mold of rear spoiler, layed up section, cut in two, re profiled to suit exhaust/ belly pan area.
(http://i114.photobucket.com/albums/n244/ukcjm/PICT4549.jpg)
Cut section for clocks, fitted had a check for clearances etc.
Cut off screen frame, replaced, added fibreglass impression.
(http://i114.photobucket.com/albums/n244/ukcjm/PICT4610450x338.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/PICT4493.jpg)
Waxed, layed up one thinned down layer of 600, to tank line, frame.
Added two layers of CF. Left 48 hrs, continued off bike.
Ground out any imperfections, refilled.
(http://i114.photobucket.com/albums/n244/ukcjm/PICT4577.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/PICT4580.jpg)
Sanded edges, cut down single strands of CF, and used in corners.
After market fairing was Raptor, possibly.
When the call of, All King Edwards horses, can manage big fences, echoed, found possible source of materials.
http://www.saddlecraft.com/materials.php
(http://i114.photobucket.com/albums/n244/ukcjm/DSC00711.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/DSC00717.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/DSC00717.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/DSC00723.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/DSC00732.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/DSC00743.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/DSC00756.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/DSC00787.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/DSC00800.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/DSC00801.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/DSC00810.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/DSC00820.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/DSC00843.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/DSC00846.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/DSC00853.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/DSC00859.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/DSC00874.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/DSC00877.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/DSC00912.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/DSC00916.jpg)
Sectioned around front centre vents, to start mold. Not much room, especially with three screws, protruding from plug.
Idea here was to try and prevent any distortion, facilitated by heat.
Used barriers to continue mold, after leaving two layers fibrglass 600, to cure.
Angles between headlight protector recesses, and side vents, are tight.
Maybe bit of a squeeze, to release mold. :icon_eek:
Decided against molding side vents separately, as figure can remove plug from mold, rather than reverse. Its not retail, so dont mind scraping by.
Then can maybe make it up on down side, with options there.
Cant seem to find suitable mirrors, so maybe chop two sets of bicycle fork shaped brackets.
Thought engine should now be removed.
Exhaust studs seized, despite treating with WD40 hot and cold, starting a good month before.
Removed engine , exhaust still attached, and asked local firm to remove fixings.
Did a fantastic job, although took engineer six hours, and resulted in hefty bill.
Stinger.
Still, a "cap" on charge was originally requested........................ bill revised, sanity restored.
:)
Man I wish I discovered this thread a few months later just so I could see the final product.
I'm sure you're just as excited as I... keep up the posts.
You do nice work too. I am impressed.
Looks very cool. Looks like you're building a fighter jet on the front of your bike.
Hey...Many thanks mr.happy & MVent0.
After a point, shaping takes on a life of its own, to the point where it can feel that observing is the only possible participation.
"The shape was always there", all we did was to rub alittle.
Its great to work through each stage.
Fair amount of nerves/paranoia...
It might take awhile for overall look to settle into mindset.
http://www.essortment.com/engineering-information-modeling-synthesis-rapid-prototyping-44988.html
http://www.fablabmanchester.org/
^ Don't ya just love technology sometimes.......
(http://i114.photobucket.com/albums/n244/ukcjm/DSC01194.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/PICT4662.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/PICT4666.jpg)
Layed up one and a half layers of 600, around "oven" .
Will sand and build up to around 5/6 layers, sanding in between.
Front guard had 6inch crack, which had to be re stuck, and used as mold.
Huge amount of crush needed, to compress CF into corners.
No bagging available, as "spur of the moment" job, so bolted guard to board, used 5 layers of CF, epoxy, silver foil, concrete dust (Sand maybe better), held guard either side, and wedged centre apart. Added weights.....kitchen sink, cupboard....chair....
(http://i114.photobucket.com/albums/n244/ukcjm/DSC01427.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/DSC01451.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/DSC01468.jpg)
Blended side panels, to frame area.
Decided seating positions.
Used marine foam to bridge front of seat, and started rails.
(http://i114.photobucket.com/albums/n244/ukcjm/th_DSC01479.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/th_DSC01509.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/th_DSC01591.jpg)
Originally thought of blending rear lights to side panels, but am gonna leave roughly in same position.
The epoxy and "yachting weave" is an effective core.
Used laminated board to extend rear wards to mount license plate. Blended in side panel front vent, stuck some foam behind rear seat, layed up, and cut foam away after resin had cured.
(http://i114.photobucket.com/albums/n244/ukcjm/th_DSC01608.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/DSC01614.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/th_DSC01640.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/th_DSC01672.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/th_DSC01694.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/DSC01725.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/th_DSC01756.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/th_DSC01771.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/th_DSC01700.jpg)
Removed fairing plug in pieces, leaving mold whole for time being.
Side panels will have to be molded. Added scrap wood strips to framing.
Copied guards.
All I can say is WOW, that looks like so much work. Good for you for taking on a project head on like that and thanks for posting the pictures. Keep it going, its looking good.
Cheers.
Thank you SS Adrelaline. :thumb:
Thankfully the various stages are all nearing completion.
Frame was cleaned up, and re coated with a mix of self etch, silver spray, epoxy, and lacquer.
Swing arm and torque bar had two layers of braiding, although first layer was mostly sanded away around clearance affected areas.
Stickers:
http://www.ebay.co.uk/itm/150925829116?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1497.l2649
Chameleon effect, red/blue, CF look.
Custom order for "GS500E", went with not highlighting lettering/numbering with color, or kevlar.
Kellaway very kindly collected engine, adjusted valve clearances, gave "top" ok.
Also asked them to remove seized bushes from cushion lever, and center stand, aswell as ordering some parts.
Re installng the engine was kinda interesting.......... :2guns:
Found advice via Google that suggested laying engine on its right side, might be the way to go.
Worked a treat.
:cheers:
(http://i114.photobucket.com/albums/n244/ukcjm/CFFINGS.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/CFFINGS1.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/CFFINGS2.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/CFFINGS3.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/CFFINGS4.jpg)
"L" shaped bracket, attached to clocks previous mounting, is pivoted, hopefully allowing fairing to be bolted on easily.
"Fuzzing" on the Kevlar is being removed as dregs of left over mixed up resin becomes available.
(http://i114.photobucket.com/albums/n244/ukcjm/DSC01833-1.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/DSC01857.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/DSC01861.jpg)
Only laying up CF in key areas, have left to set, for around a month.
Wow its really turning out! Keep us updated.
Yeah, talk about patience and dedication :cheers:
Please enlighten me on that rear wheel setup, is that stock?
:thumb:
Many thanks.
Things can/maybe will be developed, would like to take mold from tank, mold rear section in one, add original catch etc.
....and a big pot of cash... :D
Spring/shock from SV650, although was toying with potential mixing blue road spring, surplus to needs.
Later replaced with standard shock, re locating, so time restricted for now.
Did ride the GS, around ten miles round trip, to MOT, just recently, and although failed, have relatively simple tasks for road use.
:cheers:
Tried to create shape using Ally tubing/braiding etc for mirrors.
(http://i114.photobucket.com/albums/n244/ukcjm/Fairingmirrorsresized_zpsf10db1aa.jpg)
Trimmed just leaving outer strip/join, cut plastic clamp section, set plastic strip with slight curve.
(http://i114.photobucket.com/albums/n244/ukcjm/Fairingmirrorsresized1_zps30a6aa57.jpg)
Epoxied another layer/ clamped.
(http://i114.photobucket.com/albums/n244/ukcjm/Fairingmirrorsresized2_zps4dcc9496.jpg)
Started to get some shape.
(http://i114.photobucket.com/albums/n244/ukcjm/Fairingmirrorsresized3_zps1b148acf.jpg)
Shortened, tested braiding.
(http://i114.photobucket.com/albums/n244/ukcjm/Fairingmirrorsresized4_zpsba8c297f.jpg)
Inserted braiding into hole, and folded over, clamped.
(http://i114.photobucket.com/albums/n244/ukcjm/Fairingmirrorsresized5_zpsdc2a6f29.jpg)
Sized up end caps, inserts, and keyed.
(http://i114.photobucket.com/albums/n244/ukcjm/Fairingmirrorsresized6_zps7d6e5b6e.jpg)
Removed material.
(http://i114.photobucket.com/albums/n244/ukcjm/Fairingmirrorsresized7_zps3d246cc1.jpg)
Maybe try a solid, CF arm next time.
(http://i114.photobucket.com/albums/n244/ukcjm/MirrorsKoso816x612_zps26f582ff.jpg)
Test areas highlighted need to modify fairing side vents.
(http://i114.photobucket.com/albums/n244/ukcjm/FairingArticale1_zps432961e3.jpg)
Re did screen plus.
(http://i114.photobucket.com/albums/n244/ukcjm/FairingArticale2_zps66bdc99b.jpg)
Skinned vent sections, clamped to mold.
(http://i114.photobucket.com/albums/n244/ukcjm/FairingArticale3_zps22118e00.jpg)
(http://i114.photobucket.com/albums/n244/ukcjm/FairingArticale5_zps11ec8d2c.jpg)
Weighted screen in mold, sanded,added frame.
(http://i114.photobucket.com/albums/n244/ukcjm/FairingArticale6_zps70ea0ff0.jpg)
Sanded.
(http://i114.photobucket.com/albums/n244/ukcjm/FairingArticale7_zpsa5be7548.jpg)
Had small amount of seepage, although "glassing" meant this was removed easily.
(http://i114.photobucket.com/albums/n244/ukcjm/FairingArticle8_zps491b5501.jpg)
Misjudged the stretch of CF/Kev mix, and maybe width of edge, decided to correct with spray.
(http://i114.photobucket.com/albums/n244/ukcjm/FairingArticale4_zpsbf3c1e82.jpg)
Bolted in sections, layered up, sanded.
(http://i114.photobucket.com/albums/n244/ukcjm/FairingArticle9_zps19ba7b4b.jpg)
Mix added, left to cure.
(http://i114.photobucket.com/albums/n244/ukcjm/FairingArticle10_zps18675efd.jpg)
Similar process for side panel vents, although longer layed up mixed cloth in two stages, over zealous with grinder and damaged.
(http://i114.photobucket.com/albums/n244/ukcjm/Sidevents_zps1c565467.jpg)
Took a couple of mm's from gap, overnight, before laying up side panels.
(http://i114.photobucket.com/albums/n244/ukcjm/Sidevents1_zps561488f2.jpg)
Mold had stuck, small area, although did risk not separating after plug removed. Fitted to take template.
(http://i114.photobucket.com/albums/n244/ukcjm/Combined1_zps4957cdbe.jpg)
Bracket added fixing to original fixing, although no rubber,underneath, bolts/spacers either end.
(http://i114.photobucket.com/albums/n244/ukcjm/Combined12_zpseb8bac33.jpg)
Gave panels dusting of Satin, Kev' needs cleaning and edging. Left headlight protectors out for now, local shop said they'd adjust headlight without charge, so wanted to allow easy access to adjustment points. Could have maybe lined up Kev' mix better/differently. Fixed on essentials rode to MOT, although failed, distorted headlight, leaky forks/unions, no rear reflector, throttle cable raised revs- steering lock to lock , handlebar slightly loose, indicators mis matched.
Parts that couldn't be sourced locally are in post, lighting being weighed up.
(http://i114.photobucket.com/albums/n244/ukcjm/DSC02581758x582_zps8157fd52.jpg)
With re locating looming on the horizon, its a relief to now have the GS MOT'ed, and have rent.
Tidying up, source shock, attempt belly pan, will be be hard to fit in at the moment, and any other developments, mostly shelved for now.
At least my better half, and myself , can go for a ride now.
:)
(http://i114.photobucket.com/albums/n244/ukcjm/GS500EMOTeD_zps8d4def68.jpg)
Whoa! This thread exploded with awesome!! Definitely some cool custom work here
I need a photo looking straight at the front. Can't get my head wrapped around that nose cone.. Looks gnarly! Keep up the good work and photos :cheers:
reminds me of the SV fairing. sweet looking. I wish had those skills.