Ok this is my first try at modding my bike. Thought i would share how i Grilled my bike.

What you need:
1 Dremel (the best tool for modding ever)
1 onion  basket (you will see what i mean, picture provided)
1 JB Weld putty
1 chrome spray paint
1 Dry erase pen
50 pack of clear medical gloves. (i ended up using about 20 pairs) they are real cheap.
All parts were obtained from Lowe's.  (maybe this website should get some money for inserting that name here)

So here are the picture of the basket, dremel, and paint can.  I obtained the JB Weld later on thus not in the picture.




I then proceeded to cut one side of the onion basket with my dremel.
This is pretty easy to do. Just be careful you dont cut yourself. I was also wearing my paintball facemask.. long sleeve shirt as it will create sparks.

One side of the onion basket will fit one side of the fairing. Try to cut as close as possible to the outline of the onion basket to maximize the amount of metal grate you can get  out of one side. Once you cut one side out... cut that in half. in half in which there is more leghth. So i guess longways...   top half goes to the top hole the other half on the bottom hole.  I cut it right in the middle first.  This will allow me to better draw an ouline of where to cut to fit on the top hole of the fairing as the metal grate is not so big.  You then place that metal grate on top of one of the hole and outline about half an inch around the hole using your Dry Erase Pen.  Reason you use dry erase is you can clean up later very easily.  You then cut that outline with the Dremel. 

Start slow and only do 1 hole at a time.  Put the cut outline on top of the hole and slowly bend the metal around the hole.  This is where you want to take your time and really do a good job.  It allows the metal grate to rest on that area naturally and not forced making it easier for you later when putting in the jbweld.  When you are bending the tips of the grate to match the slope of the hole.. you may need to cut using your dremel part of the corners so that it bend more easily. I cant describe what that means but  maybe you will know when you are actually doing it.  Also one side of the top hole there is a plastic close to the hole that you will need to cut around so that your grate will fit better.  Dont be afraid to cut away at the grate slowly to help you bend it a certain way and such. Just do things slowly and with a plan.

Do this same exact procedure to the bottom hole.  This is the harder one as it bends down a bit thus creating an awkward bend for the grate. Just keep rubbing it down. Even use pliers to bend the ends in a bit.. If you have a hard time makig it fit naturaly following the curve.. no problem.. your jbweld will hold that grate down for you with no problem.  Its just that if you take your time to really try to follow that curve it makes it easier... but not neccessary. 

After you have shaped the grate to as close a form around the hole as you can. This is the part where you can paint the grate. I chose the chrome. But you can certainly choose your own color. Looking back..i may have done blue as well.. but i am good with this as i will be putting underlighting  next to this grate which would cause it to reflect the blue light.  Let it dry and do not hurry it.. jbweld is rather permanent and you dont really want to say oh i missed a spot or part of the paint came off your hand while putting it on.

8 hours later.

Ok now that you are done with the paint you are ready to use JBWELD .
JBWELD putty is like this tube that you cut part of it then you squish it together until the 2 different colors meld into one and becomes sticky.  You only need a very small amount for each time you squish together the JBWELD. The reason being you wont be able to use it all at once.  You take that one small amount and you put it between the grate and the fairing holding it down firmly for about 3 minutes. That should be enought time to dry. You can then cut away excess with knife..yes i said cut.. by 3 minutes it hard enought that you have to cut it to get parts off.  really cools stuff.. it basicaly dries up like litterally a rock. You should only do spots and not have to go all the way around. You may notice on the picture that i didnt put jbweld on the silver part on the bottom hole. I figured taht was close to the exhaust pipe thus gets hot... i didnt want the weld to be in that area.. because i took my time bending the grate to the form of the hole i was able to do this without messing up the look.

YOU HAVE 3-4 minutes to get this on one side of the grate before it dries.  Do it one spot at a time.  This is where you need lots of glove. you put on both glove to mesh the weld together. Once its the correct consistency,  you then take off one glove from one of your hands.. the reason... (you will want to hold down that weld onto the grate and the fairing and you will want one hand pressing down on the fairing from the inside and another hand pressing on the other side.. the hand on the other side you want your glove off as you have small amount of jbweld on it with gloves on and can stick messing up the shiny side of the fairing.   Watch those thumbs with the gloves as well as they tend to go around the hole and hold pressure  naturally on the other side but since its the glove side has jbweld on it and will get that clean side dirty.  I had to stop what i was doing many times to clean the shiny side of the fairing due to this mistake. Keep an eye out for it.

45 minutes later.

here is the final result with the grate and jbweld putty.






AND THE FINAL RESULT: GOOD LUCK TO ALL WHO TRY IT.

Cool!
Looks very nice.

PJ

Ehh...

I was wanting to see a tailgate party GS w/ a cooking grill on the back or something 

Quote from: scottpA_GS on August 14, 2008, 06:20:10 AM

Ehh...

I was wanting to see a tailgate party GS w/ a cooking grill on the back or something 

You just need steak/burger holders that clip on the cylinders. "install steak - ride 5 miles in stop and go traffic - pull over, marinate with wd40 and turn over, ride back, add a little 10W40 sauce and eat!"

Looks superb mate ... nice work 

nice write up!
thanks!

Niice job! I dig it. 

Love the mod!  I'm not sure what that "grill" material cost, but you can also pick up some Gutter Guard from Homedepot for around 3-5 dollars and do basically the same thing.  It probably isn't as sturdy as what you used, but none-the-less cheap!

Nick

Quote from: utgunslinger13 on August 14, 2008, 11:29:29 AM
Love the mod!  I'm not sure what that "grill" material cost, but you can also pick up some Gutter Guard from Homedepot for around 3-5 dollars and do basically the same thing.  It probably isn't as sturdy as what you used, but none-the-less cheap!

Nick

Yep, used the Gutter Guard on my Honda Odyssey to keep the bugs and rocks from hitting the a/c condensor.  Looks sharp, it's cheap,functional, won't rust and got 3/4 roll left over for future projects .

Bluehaze,

Nice job!

That looks really tight. I like it!

you have inspired me and i went right out to Home Depot to get materials......ooops should have gone to Lowes nothing at Home Depot! but did find some fish baskets at Wally-world that did work chrome spray paint j-b weld and some clear epoxy did the job great and like you my LED light kit is in the mail.

nice bro.. provide pictures please when you get yours all set up.

Well got my lighting in and spent the weekend hooking it up.   Here is the pic.  I lovin it..  It really makes that grill stand out now.
Not that great of image as its in nightime but this will get attention at night.. And the cloudy weather up here in the NW. Thats all i need for safety.



This second one is on the side with the headlight off..

That sure is some bright lighting. What are you using? I ordered these Led's off e-bay and got four single LED's and they just dont put out half that light ? Let me know it looks great i want t

http://www.customdynamics.com/Suzuki_tail_retro.htm     ..its a candy store for  all lighting equipment.

Looks cool.  I think I am going to have to follow suit and do this while the bike is parked for winter.  Think I might at a couple led's under the tail to hit that rear wheel area.

Naaaa ...
I Just ...
Rob a jewelrey store and tell em make me a grill. 
Cool.
Buddha.

Isn't the blue illegal? Think it looks cool but down here in Fl the cops would have a field day with fines. Was thinking another color but not sure.

Oh well,

Mary S.

I got a switch on it.. so if they dont like it.. i just turn it off.. go around the corner and turn it back on.

do you remember what kit it was you bought from them was it the sportbike kit?