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. 
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.......





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....

Blended side panels, to frame area.

Decided seating positions.

Used marine foam to bridge front of seat, and started rails.

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.

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.
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..........
Found advice via Google that suggested laying engine on its right side, might be the way to go.
Worked a treat.

"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.

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 

Please enlighten me on that rear wheel setup, is that stock?

 
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...

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.


Tried to create shape using Ally tubing/braiding etc for mirrors.



Trimmed just leaving outer strip/join, cut plastic clamp section, set plastic strip with slight curve.



Epoxied another layer/ clamped.