Busy weekend: (now with paint) belly pan, underseat tray, etc.

orangelion03 · January 29, 2011, 05:48:17 PM

Been doing some work on the bike: some rework of things changed by the previous owner, some new stuff. The original owner of the bike replaced the plastic rear fender bits with a tray made from an aluminum stop sign. I left it alone for a few months, painting it red so it didnt look like it was made from a stop sign. When I installed the SACHS reservoir shock, I had to remove the rear coil bracket, which also held the PC3 module, so I figured that since I had to remount the coil somewhere I would make a new tray and incorporate a coil mount on it. I also decided to mount the rectifier under the tray so as to open up some storage space under the seat...to keep it clean, I made a splash shield to protect it from dirt thrown by the tire. I had intended to attach the PC module in the same general area, but I decided to take advantage of all the space under the tank left by the replacement of the airbox with cones. While I was at it, I installed the belly pan I bought last week. Pretty straightforward but found two issues. On the right side, I had to add a spacer (and longer bolt) so that the mount would clear the peg bracket. On the left, the kickstand and spring interfere with the pan material and will need to be relieved for adequate clearance. I also modified the mounting slightly by adding rubber grommets between the pan glass and the mounting bracket (hopefully will minimize any potential stress and cracking). Painting will follow this week.

Tray is made from 1/8 aluminum plate, primered with Rustoleum aluminum primer, and painted with Krylon Banner Red (Rustoleum Regal Red is a closer match to the frame, but Krylon dries faster)

This shows the approx volume I can store under the seat. Could add a few tools and a rag. Need to clean up the wiring to the rear lights.

PC bracket is made from thin gauge aluminum sheet and is held in place by the battery strap

Close-up of right rear bracket showing steel spacer. All I could find at the moment, will replace with aluminum one next week.

Duck-Stew · January 29, 2011, 07:21:38 PM

Looking Good Buddy!!

DucHead · January 29, 2011, 07:25:20 PM

I've been waffling on a belly pan for years. I can't wait to see it painted!!

Billyzoom · January 29, 2011, 09:06:52 PM

Looking good!

Goat_Herder · January 29, 2011, 11:54:43 PM

Love these DIY projects. Keep us updated with pics!

Jarvicious · January 30, 2011, 07:04:55 AM

Why replace the steel spacer with aluminum? Is the spacer not stainless, or are you just looking for that .2 ouce weight loss?

orangelion03 · January 30, 2011, 08:49:34 AM

Quote from: Jarvicious on January 30, 2011, 07:04:55 AM
Why replace the steel spacer with aluminum? Is the spacer not stainless, or are you just looking for that .2 ouce weight loss?

It's rolled mild steel and should be rusty by the time I replace it with an aluminum one.

Regarding weight...my office is located at the division of the company I work for responsible for composite designs, molding, forming etc. Eventually, I will replace the aluminum one with a properly designed carbon fiber tray (already modeled it in Solidworks). Should save at least 1/2 pound.

orangelion03 · January 30, 2011, 08:49:53 AM

Quote from: Duck-Stew on January 29, 2011, 07:21:38 PM
Looking Good Buddy!!

Thanks Stu!!

Guille62 · January 30, 2011, 11:57:38 AM

well done Roberto that monster is gonna look fantastic!..Cheers from Brissie

Guille

orangelion03 · January 31, 2011, 08:39:56 AM

I'm now thinking of deleting/filling/covering/blending the little NACA ducts They are clearly cosmetic as I imagine you get plenty of air flowing through the front of the pan.

Jarvicious · January 31, 2011, 03:55:23 PM

I kinda like the ducts. They're not really at the proper angle (aesthetically) but taking a slab of uninterupted plastic and making it attractive can be tough. Maybe cut/modify the existing ones?

bunnyman666 · January 31, 2011, 04:20:48 PM

Bellypan looks familiar- Italmoto?

I couldn't get myself to pay for their brackets. How are you going to make yours?

Everything looks good!!!

RVA Duc · January 31, 2011, 04:28:06 PM

Nice bellypan , i have that same one. I put some wire mesh in the air hole areas looks good

orangelion03 · January 31, 2011, 07:42:17 PM

Quote from: bunnyman666 on January 31, 2011, 04:20:48 PM
Bellypan looks familiar- Italmoto?

I couldn't get myself to pay for their brackets. How are you going to make yours?

Everything looks good!!!

Yup, Italmoto. I purchased theirs. Believe me, they are worth it. I could have fabricated a set, but they would have cost me in time. The Italmoto parts use stainless steel tabs (dont rust and are flexible), and swaged rivet nuts. Everything lines up nicely.

orangelion03 · January 31, 2011, 07:44:07 PM

Quote from: RVA Duc on January 31, 2011, 04:28:06 PM
Nice bellypan , i have that same one. I put some wire mesh in the air hole areas looks good

Post pics please!!! Your avatar is too small to see the details!

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Busy weekend: (now with paint) belly pan, underseat tray, etc.