Frame Work

[Ranger06]

I am looking to cut off all the little mounts and things welded to my frame, namely the seat lock frame, side panel mounts, and resistor mount on the left side.  Anyone done this themselves?  How hard is it to smooth the cuts perfectly then prime and paint frame?  Can you tell there were things welded to the areas you worked on?  Part of me wants to just take it to a good body shop...if that's even an option.  Please post some pictures if any of you have done what I'm talking about. 

[kopfjäger]

This was how my 800 frame looked after it was repainted.

[TAftonomos]

I wouldn't prime/paint, just powdercoat it and never worry about it getting scuffed again  

[MotoCreations]

Cut out the offending material as required with cutoff disc.  Use a grinder to get close to the tube itself -- but don't go too far.  Then roloc disc or use a sander or even files.  Big trick with polishing out welds on tubes is to keep things moving and light pressure.  You don't want to flat spot the tube.  All welds should polish out without problem.  Worse case scenario just weld up and do it again.  Easier to show someone than to describe to be honest!

If you want to smooth out the factory welds -- talk with your powdercoater.  There are two bondos with high content metal that can be low-temp powdercoated.  Talk with your powdercoater first and make sure they are familiar with these.

Easiest method -- just smooth, bondo and paint.

I don't recommend grinding the factory tube-to-tube welds -- your opening a can of worms by doing that.  Just smooth as per above.

As for my frames?  I lightly grind the TIG weld and polish out as required.  Sometimes coming in with TIG brazing (low temp weld) and then sanding / polishing that out if required to make a nicer transition.  No bondo.  All metal.  Labor intensive and requires welding expertise. (as well as polishing expertise) Or I just paint/powdercoat over the TIG weld itself and leave it as is -- most look pretty nice to begin with.

[Ranger06]

Forgive my ignorance on the matter, but in order to powdercoat the frame, I'd have to do a complete disassemble right?  Not really an option anytime soon as I have a 90-mile daily commute.  kopfjager, your frame looks incredible, nice and clean in that area.  Thanks for the advice guys

[weemonster]

yeah compete disassemble.

Its easier than it sounds loadsa foks on here have done it.

[fasterblkduc]

yeah compete disassemble.

Its easier than it sounds loadsa foks on here have done it.

I've done it so many times that I have it down to 4 hrs. Reassmbly is a different story. 

[TAftonomos]

Only problem I see with tearing it down to the frame is the snowball effect.  For those of you not familiar with this, it's the effect caused by "well, since this is already apart I might as well do this, and this, and this...". 

Yeah, I can already see some of you thinking something else.  For those of you unfortunate enough to experiance the "other" snowball effect...I'm sorry

[Capo]

Only problem I see with tearing it down to the frame is the snowball effect.  For those of you not familiar with this, it's the effect caused by "well, since this is already apart I might as well do this, and this, and this...". 

Yeah, I can already see some of you thinking something else.  For those of you unfortunate enough to experiance the "other" snowball effect...I'm sorry

You mean I'm not abnormal, that there are others out there like me 

[DesmoLu]

Only problem I see with tearing it down to the frame is the snowball effect.  For those of you not familiar with this, it's the effect caused by "well, since this is already apart I might as well do this, and this, and this...". 

Yeah, I can already see some of you thinking something else.  For those of you unfortunate enough to experiance the "other" snowball effect...I'm sorry

+1. Specially when during the reassemble part you run out of money for the mods.... 

[angler]

Only problem I see with tearing it down to the frame is the snowball effect.  For those of you not familiar with this, it's the effect caused by "well, since this is already apart I might as well do this, and this, and this...". 

Yeah, I can already see some of you thinking something else.  For those of you unfortunate enough to experiance the "other" snowball effect...I'm sorry

Ah, the dreaded "might as wells."  Great way to end up over budget......

[Ranger06]

Ya, I can't walk by her as it is without another idea...or 10. 

There is a Harley shop down the street that says they can blend out the welds and paint it for me once I dremmel the stuff off.  I think I'll provide the paint for them though. Where do you guys get your paint from?  Anywhere special?  The owners manual says PPG 291.501 for a Dark.  Don't even want to go near the dealership with a question like that, every time I walk in there, it costs me a few hundred bucks!

[ghosthound]

is there a walkthrough on dissasembly? or a tool list?

I would imagine i would need stands at the very least.  I really wanted a red frame but since there werent any in the used market locally, i bought a yellow/black monster.  Id love to eventually get the frame red and have the tank painted white.