GS500E Custom fairing, plus Aramids.

[Rebelervi]

Hi all.
Purchased a GS500E 94.

The Suzukis maintenance looked to have been slightly neglected, every inner weld joint open to the elements.
Rode okay though...

https://i114.photobucket.com/albums/n244/ukcjm/GS500E2.jpg

https://i114.photobucket.com/albums/n244/ukcjm/SuzukiGSXR750K62006standardscreen.jpg

Purchased GSX750 Screen.

https://i114.photobucket.com/albums/n244/ukcjm/bikinifairing.jpg

Bought Raptor fairing, for light unit, and template.
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(Petition) https://moonbears.org/

[Rebelervi]

https://i114.photobucket.com/albums/n244/ukcjm/GSSeatForm11.jpg
Used laminated flooring panels, filler and Plasticine to give a base, for Carbon fiber sheet.

https://i114.photobucket.com/albums/n244/ukcjm/DSC04276719x350.jpg
Wanted to keep same rear light holder, although lens would have to go.

https://i114.photobucket.com/albums/n244/ukcjm/seatformcf.jpg

CF layed up with Epoxy, SP106, to create a form/core.
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(Petition) https://moonbears.org/

[Rebelervi]

https://i114.photobucket.com/albums/n244/ukcjm/GSSidePanel1.jpg

Side panels- Had to create a form to add shaping. Treated original panels with release wax, around 6 times. Used couple layers of Gelcoat.

https://i114.photobucket.com/albums/n244/ukcjm/GSSidePanel2.jpg

Layed up around three layers of chopped strand matt, polyester resin. Use the 600, as its easy to thin down.

https://i114.photobucket.com/albums/n244/ukcjm/GSSidePanel3.jpg

Left for around a week, and split.
____________________
(Petition) https://moonbears.org/

[Rebelervi]

https://i114.photobucket.com/albums/n244/ukcjm/SidePanelFirstcut.jpg

Cut out the start for side vents, keeping the piece removed to use as vent "Floor."

https://i114.photobucket.com/albums/n244/ukcjm/SideVentFistSideVentFloopr.jpg

Attached firmly to bike, yet easy to remove. Reinforcing with ply, and filler. Incidentally, the ink lines on ply are useful as guides, when adding and sanding the filler.

https://i114.photobucket.com/albums/n244/ukcjm/SidePanelSeatForm.jpg

Can use any junk to start filling in gap, polystyrene, carrier bags etc.
____________________
(Petition) https://moonbears.org/

[Rebelervi]

https://i114.photobucket.com/albums/n244/ukcjm/BCFSIDE.jpg

Filler creating steep sides, vent floor ready to stick while panel is on bike, so as can position to max effect.

https://i114.photobucket.com/albums/n244/ukcjm/BCFSIDE1.jpg

https://i114.photobucket.com/albums/n244/ukcjm/BCFSIDE2.jpg

Wavy but okay for now.
____________________
(Petition) https://moonbears.org/

[Rebelervi]

https://i114.photobucket.com/albums/n244/ukcjm/BCFSIDE3.jpg

Fiberglass,to create a bed, and start to bring forwards, frame protected from resin/filler.

https://i114.photobucket.com/albums/n244/ukcjm/BCFSIDE4.jpg

Removed, trimmed.

https://i114.photobucket.com/albums/n244/ukcjm/BCFSIDE5.jpg

The CF seat panel core is starting to go wafer thin, cheesing, which will help any adding of CF later on.
Ran the line down from tank edge, to Gelcoat on side panel plug, hence hole.
____________________
(Petition) https://moonbears.org/

[Rebelervi]

https://i114.photobucket.com/albums/n244/ukcjm/BCFSIDE6.jpg

Work all the lines with , 80 grit abrasive paper, the easy sand filler is very workable with chisels, and alike.
Simply sweeping the filler with abrasive, creates a good finish , and the paint is just extra filler at this point.

https://i114.photobucket.com/albums/n244/ukcjm/BCFSIDE7.jpg

Trimmed bottom line, left rear of panel for now.
The front still needs matching to frame, and forward vent.
Originally, considered laying CF over plug, but it seems beneficial to take a mold.
____________________
(Petition) https://moonbears.org/

[Tim..]

Good work!

Whats the final goal you're trying to achieve?
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Project builds: My VFR400 nc30 build thread + Honda Britain Rep VFR + What? Another VFR +Project 'cos I want one' + V8 coffee table
www.marshallracing.co.uk
OCD - Helping to bring the standard of my bikes up and make me slowly go mad since 1999

[t121anf]

Looks good so far, be nice to see the finished product.

[mysterious_rider]

How strange, the gs runs a steel frame so welding a new subframe would have been a piece of piss. Although I wanna see the outcome.

Looks good.
____________________
KAWASAKIIIII

[AL-]

Good work. Looking forward to seeing it finished

[mintex]

Doing well bud, i will watch this one with interest

[Rebelervi]

Hey...Heartfelt thanks one and all.
Your hospitality is greatly appreciated.

Tim...The only goals, or achievements in mind, are to experiment, and hope to encourage others.
https://i114.photobucket.com/albums/n244/ukcjm/cheers-1.gif

https://i114.photobucket.com/albums/n244/ukcjm/Headlight1.jpg

Raptor (?) Aftermarket fairing stripped down - Wanted to keep headlight unit up the right way, but turn the shaping it was held in, upside down. So could use the fairing as a mold.

https://i114.photobucket.com/albums/n244/ukcjm/Headlight2.jpg

Any edges made CF snag, and after working CF into shape, would only be left with a Horse shoe shaped item.

https://i114.photobucket.com/albums/n244/ukcjm/Headlight3.jpg

Adding a divide between lights, might add to character.
____________________
(Petition) https://moonbears.org/

[Rebelervi]

https://i114.photobucket.com/albums/n244/ukcjm/Headlight4.jpg

Pulled from the fairing, which I still treated with release wax, despite it being plastic, i needed to turn up other way, on flat laminated board and add a top surface.
https://i114.photobucket.com/albums/n244/ukcjm/Headlight5.jpg

Could know trim to one edge of the light unit.

https://i114.photobucket.com/albums/n244/ukcjm/Headlight6.jpg

Layed up another couple of layers, joined to front curve, which pulls up allowing light unit to be removed.
____________________
(Petition) https://moonbears.org/

[Rebelervi]

https://i114.photobucket.com/albums/n244/ukcjm/Headlight7.jpg
With unit held at top, the lower line sat into light unit recess.


https://i114.photobucket.com/albums/n244/ukcjm/Headlight8.jpg

Sourced two Lucas lenses, cut down, and used some Airex core material, to start the central divide.

https://i114.photobucket.com/albums/n244/ukcjm/Headlight9.jpg
Added some "yachting" weave fibreglass, as core,and continued with CF, and all with SP106.
____________________
(Petition) https://moonbears.org/

[pdg]

This project is quite interesting, looks like you're putting some decent thought into it.

[Rebelervi]

https://i114.photobucket.com/albums/n244/ukcjm/DSC05632768x576.jpg

Purchased CF braiding.
In addition Kevlar strip and BMW light protector.

https://i114.photobucket.com/albums/n244/ukcjm/PICT4330.jpg

Would need a temporary/prototype fairing, jigged the screens, GSX and Raptor, to sections of plastic.

https://i114.photobucket.com/albums/n244/ukcjm/PICT4336.jpg
Plastic slitted, and junk to fill, ready for glass
____________________
(Petition) https://moonbears.org/

[Rebelervi]

https://i114.photobucket.com/albums/n244/ukcjm/PICT4340.jpg

Keys in the plastic made for a sturdy, item. Slits gave plastic reasonable curve.

https://i114.photobucket.com/albums/n244/ukcjm/PICT4379.jpg

The BMW light protector, was heated in oven, at around 110 c for around 2 - 4 minutes, then wrapped around light unit.

Layed up some Gelcoat + glass within the curve,, pulled, and cut from the curved protector an area for two individual protectors to be set into custom faring.
____________________
(Petition) https://moonbears.org/

[Rebelervi]

https://i114.photobucket.com/albums/n244/ukcjm/Attahfairing-1.jpg

Used "L" shaped Laminated panels, as mold to fabricate CF and epoxy bracket.
Added castor pins.

https://i114.photobucket.com/albums/n244/ukcjm/Attahfairing1.jpg

Scrap ally plate to join.


https://i114.photobucket.com/albums/n244/ukcjm/Attahfairing2.jpg

Re positioning clip ons, made GS go from Transport, to a Machine.
Temporary fixings sought, ready for all to be fitted.
____________________
(Petition) https://moonbears.org/

[Rebelervi]

https://i114.photobucket.com/albums/n244/ukcjm/ProtofitFairing.jpg

Fortunately I had a seat plug, from a previous project (Bucket seat) layed up a seat panel to duplicate.
Layed some CF against the frame, treated with wax, leaving epoxy untill tacky, before applying CF.

https://i114.photobucket.com/albums/n244/ukcjm/ProtofitFairing1.jpg

The impression taken from a headlight protector (Similar/ same as BMW K1200S 2005-2010 ) attached to larger assembly, bolted using the original headlight brackets, and gauge panel.
Cut two individual protector covers, applied resin to set into panel and removed.
Took impression of GSX screen, fitted, fillered.

https://i114.photobucket.com/albums/n244/ukcjm/ProtofitFairing2.jpg

A section of laminate had stuck, happens rarely, but does remind to use wax sufficiently even on " Non stick" surfaces.
Ran bike for awhile, was able to adjust "on" pivot/ castor pins.
____________________
(Petition) https://moonbears.org/

[Rebelervi]

https://i114.photobucket.com/albums/n244/ukcjm/FairingPlug.jpg

Had to fix the sections to bike & cut/fit some ply cross sections.
The forks were treated with one coat of release wax before using cellophane.

https://i114.photobucket.com/albums/n244/ukcjm/FairingPlug1.jpg

After an eternity of measuring, the lower panel was bracketed under neath, the ply set squarely, could then manipulate edges.

https://i114.photobucket.com/albums/n244/ukcjm/FairingPlug2.jpg

No plans. No strategy. No drawings. No restrictions.
The Grinder is always close.
____________________
(Petition) https://moonbears.org/

[Rebelervi]

https://i114.photobucket.com/albums/n244/ukcjm/FairingPlug3.jpg

The ply is the same as drawing a line, the filler suitable workable, not to disturb the guide it represents.

https://i114.photobucket.com/albums/n244/ukcjm/FairingPlug4.jpg

Picked line on clip on.

https://i114.photobucket.com/albums/n244/ukcjm/FairingPlug5.jpg

Added lower section.
____________________
(Petition) https://moonbears.org/

[Rebelervi]

https://i114.photobucket.com/albums/n244/ukcjm/FairingPlug6.jpg

Wanted central lines to reach down.

https://i114.photobucket.com/albums/n244/ukcjm/FairingPlug7.jpg

The two indicator surfaces, were fillered using templates, keeping curve regular.

https://i114.photobucket.com/albums/n244/ukcjm/FairingPlug8.jpg

Key areas all measure up, black invaluable to gauge surface.
Screen edges removed, allowed for small amount of adjustment.
____________________
(Petition) https://moonbears.org/

[Rebelervi]

https://i114.photobucket.com/albums/n244/ukcjm/FairingPlug10.jpg

Rear ply was stuck to top of forks, measuring aided by "n" template.

https://i114.photobucket.com/albums/n244/ukcjm/FairingPlug11.jpg

Edges just an extension to lines already set.


https://i114.photobucket.com/albums/n244/ukcjm/FairingPlug12.jpg

End of plug in sight.
____________________
(Petition) https://moonbears.org/

[Rebelervi]

https://i114.photobucket.com/albums/n244/ukcjm/FairingPlug13.jpg

Finishing edges and decided line around clip on.

Possibility of using multi colors, in final article, found:

https://www.ecfibreglasssupplies.co.uk/c-928-decorative-cloths.aspx
____________________
(Petition) https://moonbears.org/