Okay so basically, I am in the process of selling my 2005 GS500F and upgrading to a 2012 Kawasaki Ninja ZX6-R. The thing is, the previous owner dropped it a couple times so there are some fairing cracks and what-not and one of the turn signal stems had broken in half and was held together by gorilla tape. Yesterday, under the influence of alcohol, I decided to be brave and fix the turn signals and make them look better. I figured that i couldn't possibly make it any worse than it is :thumb:. Thus, my flush mount project began.
Once i semi-completed the project, i decided that id share my success with you guys. I wish i had taken more pictures, but i didn't. Sorry bout it. Read on for the step by step guide.
Materials needed:
Basic tool set for removing Turn signals.
Dremel Tool.
Clear Sealant.
Duct Tap
Beer.
Step One: Remove the turn signals. (I wont go in depth in to this because i'm sure there's a guide somewhere. Plus its super easy.
Step Two: Take the turn signal assembly apart. This basically consists of removing three screws in total and pulling the sinal wires through the black signal housing. You will be left with just the orange signal piece and the light bulb housing.
Step Three: Use a small grinding wheel with your dremel and cut a square out around the turn signal holes in the fairing. (wear eye protection and long sleeves. The plastic cast off is hot and sharp so it hurts on your skin and hurts worse in your eye. Trust me.) (IMPORTANT: When you make this square. the left side needs to be shorter than the right side. This is because the turn signal tapers on that end and you dont want any ugly gaps. Which i actually have because i didnt think about this at first. you can barely see them though because they are on the under and the sealant filled them really well anyway.)
Step Four: Use a little cylinder shaped sanding head with your dremel to slowly round out the edges of your square so that the signal bulb housing will drop right in. Shave off small amounts at a time to avoid making the hole too large. Basically, you want the housing to fit in snugly, and you want the lip of the orange lens to rest flush again the fairing.
Step Five: Hold the signal in place and apply the sealant. (I used silicone sealant because i originally wanted the signals to be removable so that there was easy Access to the bulb. However, i didn't realize id be cutting in to the fairing. The way this is done, its actually really easy to access the bulb. Easier than it was factory.) Use the duct tape to hold the signal in place while the glue agent you used dries.
Step Six: Wait for the glue to dry and then remove duct tape and observe your handy work. Be proud of yourself! That's basically it guys. Its a pretty straight forward project and only takes an hour or two if you don't count drying time.
Im going to throw in some pictures so that you guys can see what it will look like. By the way this project only cost me $6 since i already had the tools necessary. i only had to buy the sealant.
(http://s18.postimage.org/iou6f9zsp/photo_1.jpg)
Side view of my handy work :)
(http://s19.postimage.org/oe7m9uz2r/photo_2.jpg)
Front view. Still gluing the ride side.
(http://s19.postimage.org/v5y1cpo2b/photo_3.jpg)
Broken peices of fairing and tools and such.
(http://s19.postimage.org/z3pwfv09f/photo_4.jpg)
The dremel and heads that i used.
(http://s19.postimage.org/sejczuexf/photo_5.jpg)
The sealant i used. The bond is actually really strong. the first signal i did yesterday and let dry overnight and it is holding very strongly.
Let me know what you guys think! This is my first guide so be kind haha. Thanks!
Good job! I really like it.
Although most would be hesitant to cut up their fairings too much.
Yeah I felt the same way but I was confident that I could make it work. It helped that the fairing were already cracked. I'd have been more hesitant if they were pristine.
i thought there would be more interest lol :P. Since i havent seen this done before on this forum.
How necessary is the beer for this? :cheers:
It really helps for getting up the nerve to make that first cut haha. After that it's easy because there's no turning back :).
Good job. I think it looks ok. Easy fix for someone with a busted stalk. :rstar:
Thanks! Yeah im not sure I would have done this had the signal arm not been busted. But regardless I think it's much better than stock anyway IMHO.
It doesn't look horrible but to save $4? Then it seems if the new owner wants stalks they're screwed.
Or for $8 do this and no drilling?
(http://i490.photobucket.com/albums/rr264/Toogoofy317/IMAG0219.jpg)
(http://i490.photobucket.com/albums/rr264/Toogoofy317/IMAG0483.jpg)
I'm also concerned is the bulb just leaning up against the plastic what is holding it away from the plastic?
Mary
No offense meant to OP, but I stopped taking the modification seriously after reading that the decision was made under the influence of alcohol.
I've done too much stuff I've regretted that all seemed like good ideas while under the influence. :angel:
Good choice man, bike looking good!
Mary, I don't really know what "this" is. I see that there are flush mounts but the lack of information doesn't help anyone who is interested in being cheap but still not not cutting. Maybe you could give more info and help some people out?
Also, the bulb itself is encased in a plastic housing. The housing is what is glued to the fairings and the bulb itself is much more accessible than it was before.
You wear eye protection and long sleeves while dremmeling, but no shoes? :nono:
I think It looks pretty darn good. I don't like any of the aftermarket flush mount signals I've seen, but those look like they could be stock.
I was thinking about using the stock turn signal holes in the fairing for some fog lights and getting mirrors with indicators built in, but I might just have to do this instead of the mirrors.
Let us know if bulb life is affected.