Having ridden the GS, daily since picking Feb, we came to a few conclusions.

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.  

"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.  

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.

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.



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.


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.

Basic start of seat.
Decided, that for us, this was best place to start for accumulated panels etc.



Wish to experiment a little with shaping, so have cut open old saddle, and will see how seat feels.

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...

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

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.


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.


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.


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 1
Part 2
Part 3
Part 4
Part 5

Quote from: pave_spectre on April 19, 2011, 12:46:31 AM
You may find this article series interesting/helpful.
Part 1
Part 2
Part 3
Part 4
Part 5

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)




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.



Adding wool tufts to the DIY sections we wish to fabricate does seem even more appealing now.

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.

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.



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.

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.

Re positioned/mounted some of electrics.
Will tidy up and finish when bike is stripped.
Used threaded rivets for hooks.



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.

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.....

Quote from: mister on April 28, 2011, 01:28:05 PM

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!

 




Paper, chisel and liquid filler, paves the way......



.......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?