Author Topic: How to fenderectomy, tail tidy, rear fender removal etc...  (Read 322 times)

Offline brucedavidculver

  • Formula Extreme Racer
  • ***
  • Posts: 156
  • Karma: +13/-0
How to fenderectomy, tail tidy, rear fender removal etc...
« on: February 17, 2020, 05:44:10 AM »
Since I couldn’t find a comprehensive start to finish fender-ectomy thread (I did see plenty of “here’s what it looks like when its done,” types), I though I would post my version of a “how to” in case anyone wants a simple and cheap (a.k.a., pretty much free) way to get rid of the rear monstrosity.  It ends up being very clean, as it also gets rid of the side cargo rails, or whatever they are called, along with the little “trunk space” for the tool kit that hangs down below the tail (but doesn’t eliminate it altogether).  It also requires about zero tools (just metal shears and a hacksaw) so anyone can do it.  So without further delay…

Start by simply disassembling the back of the bike… removing the rear cowl, disconnecting the signals, removing the rear fender/subfender and side cargo rails.  I find it’s easier to remove, modify and reinstall the cargo rails one at a time so that the taillight stays connected and stays in the correct position as you work with it.  When you remove each cargo rail, cut off everything but the taillight mount (see pic) and then re-install each in turn (after a quick shot of black paint on the newly created bare metal).  You can leave the rear mounting bolts on either side a little loose, as you’ll be able to get to them even after everything is reassembled in case you need to adjust the angle of the taillight.  Save all hardware as you go (including the little metal piece that hooks the rubber band that keeps the tool kit in place).
« Last Edit: February 17, 2020, 09:31:50 AM by brucedavidculver »
2006 GS500F (latest project and probable "scrambler-type-thing")
2005 GS500F (“café-ish"mod)
2017 Benelli TNT600 SOLD
2004 GS500F (scrambler mod) SOLD
2009 GS500F (street fighter mod) SOLD
1982 GS450 (café racer mod) SOLD

Offline brucedavidculver

  • Formula Extreme Racer
  • ***
  • Posts: 156
  • Karma: +13/-0
Re: How to fenderectomy, tail tidy, rear fender removal etc...
« Reply #1 on: February 17, 2020, 05:45:20 AM »
Next move on to modifying the fender / subfender itself.  With a Dremel (or a good set of metal shears) remove the back portion of the fender as shown… a straight cut right behind the wheel well and then a little cleaning up on the sides will get you what you need (see pics).  Cut a slotted hole (big enough for a 6 mm bolt) on either side of the back of the subfender, 138mm c-t-c.  Save the remainder of the back of the fender for the next step. 
« Last Edit: February 17, 2020, 06:41:42 AM by brucedavidculver »
2006 GS500F (latest project and probable "scrambler-type-thing")
2005 GS500F (“café-ish"mod)
2017 Benelli TNT600 SOLD
2004 GS500F (scrambler mod) SOLD
2009 GS500F (street fighter mod) SOLD
1982 GS450 (café racer mod) SOLD

Offline brucedavidculver

  • Formula Extreme Racer
  • ***
  • Posts: 156
  • Karma: +13/-0
Re: How to fenderectomy, tail tidy, rear fender removal etc...
« Reply #2 on: February 17, 2020, 05:46:05 AM »
From the back part of the discarded fender, cut and drill a 163 mm square piece of plastic as per the diagram.  The diameter of the round cut out is approximately 190 mm. I use the lid from a 7” sauce pan to trace the arc and then cut it out with metal shears (but you may be more high tech than me so by all means do your own thing… lol)
« Last Edit: February 17, 2020, 10:10:07 AM by brucedavidculver »
2006 GS500F (latest project and probable "scrambler-type-thing")
2005 GS500F (“café-ish"mod)
2017 Benelli TNT600 SOLD
2004 GS500F (scrambler mod) SOLD
2009 GS500F (street fighter mod) SOLD
1982 GS450 (café racer mod) SOLD

Offline brucedavidculver

  • Formula Extreme Racer
  • ***
  • Posts: 156
  • Karma: +13/-0
Re: How to fenderectomy, tail tidy, rear fender removal etc...
« Reply #3 on: February 17, 2020, 05:47:06 AM »
All you need now is a bit of hardware for reassembly: four 6 mm fender washers (or equivalent), two 6 x 15 mm bolts and matching nuts (I like nylock).

Reinstall the subfender securely with all three original bolts, then slide your new piece into position from the back of the bike. Secure it to the top of subfender with the 6 mm bolts, nuts and the fender washers.  Next attach it to the modified taillight mounts with the original hardware.  Don’t forget your little “giant rubber band hook” thing.  Don’t snug the hardware until the cowl is back in place.  The new piece will bend into place as you final tighten it later.   
« Last Edit: February 17, 2020, 06:42:54 AM by brucedavidculver »
2006 GS500F (latest project and probable "scrambler-type-thing")
2005 GS500F (“café-ish"mod)
2017 Benelli TNT600 SOLD
2004 GS500F (scrambler mod) SOLD
2009 GS500F (street fighter mod) SOLD
1982 GS450 (café racer mod) SOLD

Offline brucedavidculver

  • Formula Extreme Racer
  • ***
  • Posts: 156
  • Karma: +13/-0
Re: How to fenderectomy, tail tidy, rear fender removal etc...
« Reply #4 on: February 17, 2020, 05:49:43 AM »
Finally, reinstall the cowl and snug up all the nuts / bolts holding everything in place.  You may need to tilt the tail light up or down as you reinstall the cowl to get the new piece of subfender to slide under (technically “above” as you are looking from the bottom) the piece of black trim on the bottom of the cowl.  You can reach up with an open end wrench from the back once everything is assembled if you need to tighten the taillight mounts.

At this point, options for your license plate and signals are endless.  A generic tail tidy like the one pictured below ($9 from eBay) can be mounted to the “new” part of the subfender for both the license plate and the signals, or like in the case of my latest bike, the PO had already relocated the signals to the cowl, so all I needed were two small mounts (I used bicycle reflector mounts) to attach the license plate to the subfender.
« Last Edit: February 17, 2020, 06:44:12 AM by brucedavidculver »
2006 GS500F (latest project and probable "scrambler-type-thing")
2005 GS500F (“café-ish"mod)
2017 Benelli TNT600 SOLD
2004 GS500F (scrambler mod) SOLD
2009 GS500F (street fighter mod) SOLD
1982 GS450 (café racer mod) SOLD

Offline brucedavidculver

  • Formula Extreme Racer
  • ***
  • Posts: 156
  • Karma: +13/-0
Re: How to fenderectomy, tail tidy, rear fender removal etc...
« Reply #5 on: February 17, 2020, 05:56:52 AM »
Ta-da! Done and done. All the ugly stuff is now "gone daddy gone" but there's still a bit of storage space for the tool kit, a little blue man-purse (or lady-purse... gotta stay PC) with your registration, insurance card or whatever you like... lol.

Hopefully someone will find this useful.  Suggestions are welcome.  I’ve done this on three bikes now but there’s always room for improvement.
« Last Edit: February 17, 2020, 09:59:04 AM by brucedavidculver »
2006 GS500F (latest project and probable "scrambler-type-thing")
2005 GS500F (“café-ish"mod)
2017 Benelli TNT600 SOLD
2004 GS500F (scrambler mod) SOLD
2009 GS500F (street fighter mod) SOLD
1982 GS450 (café racer mod) SOLD

Offline ShowBizWolf

  • Ninja turtle...in a van
  • MotoGP Racer
  • ******
  • Posts: 2692
  • Karma: +72/-0
  • Support Shelly's rescue at tinykittens.com
Re: How to fenderectomy, tail tidy, rear fender removal etc...
« Reply #6 on: February 17, 2020, 10:59:50 PM »
That looks great! Very detailed write-up too. I think I'll add it to the wiki :cheers:

The ones I've seen in the past (as well as my own) have just been trimmed up with a Dremel tool or the like. I made mine flush with the stock "storage" space and then made 2 brackets for the license plate.
Superbike bars, '04 GSXR headlight & cowl, DRZ signals, 1/2" fork brace, 'Busa fender, stainless exhaust & brake lines, belly pan, LED dash & brake bulbs, 140/80 rear hoop, F tail lens, SV650 shock, Bandit400 hugger, aluminum heel guards & pegs, fork preload adjusters, .75 SonicSprings, heated grips

 

SMF spam blocked by CleanTalk