Fractured Lacerations - Build - I Broke my Knife!

[Dusty-Dave]

Seems to me that the seat frame needs some holes. Proly bigger than the frame holes.
Dusty

[Customize IT]

Dusty I agree!

The tank the seat pan and the fender will all have holes placed in them.

I need to get all the parts together to know where to put them.

[Customize IT]

Went and bought 3/16 round bar to run the edge around the mudguard. Made the set pan and decided just to make it a fixed seat pan.

When I took the mudgaurd off to start fitting and welding I put the seat pan back on. Now sure I like it more without the mudgaurd at all.



Welded a divider in and put a 3/16 edge around it.

Then made some holes I have to plug up?

[Customize IT]

I have the simulated holes almost done. Just got to take tank back to tig weld it.

[2Loose]

DamnMan, you are a glutton for punishment, that's a whole shitload o' work yer doin' there....

Lookin' good though, been enjoyin' just watchin'....
And sometimes less is more....



There may be days when ya wanna ride, and not get yer backside all wet and muddy, might be good idea to make that rear mud guard an easy add-on when ya look out the window and see rainy weather, but ya wanna go ride anyways, might be damn handy to have some quick n easy way to attach that mud guard, jump on and hit the road, and at least keep yer backside a bit drier and cleaner, been there myself, when I sure wished I had something like that....
Aloha,
Willy

[Customize IT]

Thanks!

Got the handle bars done after 7 attempts.

I hate making handlebars always takes a dozen before I find something that will work and I like. It is comfortable to ride and works with all the parts while allowing turning.

[gearhead1951]

You know you could have mounted the all of the hydraulic stuff on the inside of a fork leg and run a short cable to it from the bars ! Much cleaner lookin' !

[Customize IT]

Ya I know I may redo the throttle and grips along with that just needed the main tube there to use.

I got my seat pan fixed down.

[Customize IT]

I got the fork legs off and braced the lower mounts for strength.
Also while apart made the steering stops.

[Customize IT]

I went to a car breaker yard today and searched for about 2 hrs for a light fixture I could use for my headlight. Found a honda civic that fit all the things I wanted for it. Had to be new style bulbs, right shape fixture, have wires for low and high beam, 50 and 65 watt bulb, right type on mount for bulb, and straight wires off the connector. Still not finished have to go get some stand off to finish the headlight mounting side.

I found it on a wrecked car and paid 10$ for the whole housing and wiring pigtail. He looked at me funny because he did not sell ever a broken part off a wrecked car! Did not even unbolt it just ripped it off! But, was exactly what I wanted.



Cut and ground all the mounting tabs off.



Made a mark to cut the inner bucket of light to shape.





Cut that part out with grinder.



Then began working on the dash to remove the tach.





Removed the mounting bracket and cut free the mount I wanted.







Removed the edge trim from the stock dash panel to reuse on trimmed bucket.





Super glued it to bucket.



Made a paper templete between the 2 parts.





Marked out on sheet steel.



Cut that out.



Welded and hand shaped the main housing.







Made a 3/16th round bar ring hand formed for the tach to mount to.



Welded to housing.





Ground welds.





Fit and welded the tach mount in.









Were I am at now. Will finish other side mounting tomorrow but, need to get stand offs and bolts.

[krymis]

metalshape a club style fairing. Good shaping experience and would carry over the look.

[Customize IT]

I do not want a fairing.

Getting closer on my headlight.
Bezel to make and some of my normal stuff with this bike to add still.
Then the mount to make.

Started by making the plate the bucket will be held in place by.



Then added edge trim to that.





Showing the bucket from the rear with the holding plate.



Made the ring for the mounting stand offs for bucket.





Welded to housing.



Made the plate that will hold the bucket from the front side.











Drilled the holes for the mounting bolts for the plate.





Welded standoffs.



Made the outer part of housing.



Welded



Cut the mounting plate for bezel and lense.



Drilled it and aluminum bezel and plastic together.



Cut out plastic lense.





Welded nuts to back off plate.



Welded plate in housing.





Need to get a jig saw to finish the bezel. Will source one tomorrow.

[Customize IT]

I did not get as far as I wanted last night on my headlight. Still not finished but the bezel is done.

Found the distance I would need for bezel.



Recessed bolt heads in billet plate.



Cut the shape out.



Ground to match main housing.



Marked the inner bezel shape.



Drilled hole for jigsaw blade to go in.



Cut out the inner part.





Ground by hand to shape and installed.

[Jeff L]

I like the bars man (get a better look at them here)

[Customize IT]

Thanks!
What angle you want Jeff?


Got the holes in the headlight done.

Marked them out the green marks not the black ones. It is real tight in here had to think it out a bit.



Drilled them.



Drilled and sawed the pieces.





Welded then ground them.



Welded in housing.



Had to notch inner ring.



Ground down welds.



Finished unit I think well maybe.





Testing on the bike.