Making my own trackday fairings!

[AngelGrinder]

At the start of the year I was forced off the road by a kind person in a people carrier, which ended up in the front and rear fairings being damaged, and then left to sit in the garage.

While sourcing replacement parts, someone had some rashed side fairings to sell aswell, so after buying those, I had a full set of spare (but damaged) plastics.

I bodged most of it together for the trackdays in summer, and while they did the job, they didn't look so great. So, over the winter I'm going to (try) and make them alot better.

I already have used fiberglass and filler to fill the headlight holes in, but will be re-doing the whole lot over winter as they weren't great.

Once they are all done, I will be taking them to my dad's to use his compressor to spray them!

Anyway, I havn't really done this before, so feel free to offer advice!

All cracks and breaks have been repaired using either or a combination of P40, araldite and a soldering iron.

So, today I decided I want to get rid of the pillion seat, and create a one piece seat fairing.

To start I go the rough shape that I needed with some aluminium mesh, and used a staple gun to fix it in place.

https://i6.photobucket.com/albums/y209/angelgrinder187/DSCF1903.jpg

https://i6.photobucket.com/albums/y209/angelgrinder187/DSCF1904.jpg

Next I used 2 bits of wooden dowel to allow me to screw the fairing on, I obviously didn't want to no be able to attach the fairing, so the dowel leaves the 2 holes needed to do this. In the future I am hoping to find a plastic tube or similar that fits in and I can glue in.

I attached the dowel to the fairing mounting points at the bottom with screws and washers, and covered the wood in a rubber glove so I can get it out when the fibreglass has set!

https://i6.photobucket.com/albums/y209/angelgrinder187/DSCF1905.jpg

https://i6.photobucket.com/albums/y209/angelgrinder187/DSCF1906.jpg

Next comes the fun/annoying part...fibreglassing. This stuff is amazing....but so annoying, it goes everywhere!

https://i6.photobucket.com/albums/y209/angelgrinder187/DSCF1907.jpg

https://i6.photobucket.com/albums/y209/angelgrinder187/DSCF1909.jpg

Will see how it looks when it's dried, then I'll see if it needs more fibreglass, or if I shall start applying the filler!

Any tips or advice from anyone?

Also, I'm not bothered about weight or anything, I'm just into trackdays and want them as a cheaper option than crashing in my road plastics! And I'm bored and wanted to have a go/learn some new stuff!
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Currently Riding - 2002 Aprilia RSV1000 Mille

[Whosthedaddy]

Looking good so far.
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Current : MSX 125 Past : CBR 900RR Monkeybike : c50 LAC : ZXR750 H2 : FZR600 : ZX7R P3 : YW100 : TRX850: Trophy 900 T309 : GSXR 600 L0: Monkeybike : XJ6S Whosthedaddy

[Gazdaman]

Looking good, it's easy to make fibreglass look really really bad.

This is an attempt a mate of mine made. It's a Corn Flakes box underneath.

https://photos-f.ak.fbcdn.net/photos-ak-sf2p/v71/142/44/518180216/n518180216_271981_3332.jpg

Gaz

[Simple]

[AngelGrinder]

I like the cereal box Would have probably been alot less messy than the aluminium mesh - all the resin seeped through and is everywhere!

Also, we have already reached problem number one....not enough hardener. It was still sticky yesterday, but seems ok tonight, going to give it another day to harden, hopefully will be ok to start sanding tomorrow!

Also, had a panic when I realised the subframe may not fit into the new space, but I have checked and we are all good!
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Currently Riding - 2002 Aprilia RSV1000 Mille

[Wafer_Thin_Ham]

Looking good.

Reminds me I need to spray mine actually. A trip to Halford is on the cards.
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My Flickr

[Simple]

[TimNorwich]

Gotta love Pauls cereal box, kellogs?
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Speedshite 50cc > Honda XR125L > Kawasaki GPZ 500 S > 02 Honda Hornet > 05 Honda CG125 winter hack > 04 Kawasaki ER-5 > 99 Honda Hornet 600 > Kawasaki GPZ 500 S > 99 Honda Hornet 600 > 05 Honda CBR600F > 01 Honda Hornet

[Resident Yank]

Good job on the single seat cowl, it looks like it will come out quite nice. I have to make an undertail for an SV race tail and that mesh has given me some ideas. Just for future reference another way that a mold can be made is to make a rough frame using wooden dowels, bits of metal, or even cardboard, then stretch fleece over them. This will give you a very flat, uniform surface that is sometimes hard to get with a mesh that tends to bend. You then soak the fleece in fiberglass resin and let it harden. From there lay up a few layers of glass to strengthen it and move on with your body filler. Many custom speaker box builders here in the US use this method. Also... there is a product that is called "kitty hair" in the US, I'm sure you have an equivalent over there, its basically a glass fiber reinforced body filler. Use this to build up any large areas, more durable and chip resistant than regular body filler, especially if you are going over 1/4 thick. I just used it to fill in voids when fitting a GSXR 750 windscreen to an SV650 front race fairing. Its good stuff.
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Snooping in from the US, don't kill me.

[AngelGrinder]

[AngelGrinder]

Oh, and this is probably how the paint scheme will look...

https://i851.photobucket.com/albums/ab71/MattRock77/sol_daytona.jpg
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Currently Riding - 2002 Aprilia RSV1000 Mille

[Mystery]

[Resident Yank]

[don]

Hi, looking good!

The reason some fibreglass feels sticky is there are two kinds, those with a surfacing wax and those without, this is to make a film over the grp to get it to set properly.You can get over this by covering it in some plastic,before it sets, then removing it when its set, but using a random orbital sander will take the stickyness off.
If you cover the grp or p40 with clingfilm you can use a straight piece of wood, or a template to help push and shape the grp. you have to sand off the clingfilm but it saves a lot of shaping and fillers.You can also use bendy plastic which has been waxed,and gaffa tape, but do not use any polish with silicone in it.floor polish works, or turtle wax.

You can use a waxed plastic sheet as a mould, apply grp to the sheet, then bend,(pre score with a knife or heat up if needed) onto the seat, plastic side down, grp up,errr...with the seat upside down... gaffa or bungee on, when set, trim up.This gives a flat surface which is much easier to work on.
As p40 sets quite quickly, you could do the seat top first, then trim off, then do the sides, it keeps you focused on one area and is less messy than the "octopus wrestling" that can happen!
Best of luck
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cbr600

[Pussy Magnet]

thats is such a good topic just keep laughing when i see the pciture and when you look you can actaly tell its a cereal box

[don]

WELL, A CEREAL BOX IS JUST A STARTING POINT FOR LOTS OF THINGS TO USE:

A BUNCH OF BANANAS

LUNCH BOX, WITH LID

PAIR OF OLD TRAINERS

CYLINDER HEAD

CHRISTMAS TURKEY

BAG OF FERRETS

EMPTY 6 PACK

OLD BRA

LAST NIGHTS KEBAB

OLD TOILET ROLL INSIDES

SPAGHETTI

PASTA SHAPES

CLAM SHELLS

ROADKILL

TRAFFIC CONE

DEAD GRANNIES ASHES

GARDEN GNOME

TOOLBOX

CALAMARI FRITTERS

DEEP FRIED PIZZA

A COD

KIDS TRICYCLE

STRIMMER

HMMM,,, THAT GIVES ME AN IDEA,,,,,,,,,,,
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cbr600

[AngelGrinder]

Just a quick update...I am seriously fed up with this now

Got the fiberglass and filler to have it smooth, but it wasn't flat, so I bought some plastic sheet used for modelling, and it's flat now, but no matter how miuch glue, fiberglass or filler I use, the edges still keep peeling off...


Anyone got a 675 rear seat unit to sell?
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Currently Riding - 2002 Aprilia RSV1000 Mille

[Bishbash]

What? I just read all that to see you're giving up....That's lame dude.


Come on, I want to see this done....No-one likes a quitter.
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My current bikes are - YZF-R1 & GS 500 E

Trackday videos - https://www.youtube.com/user/bishbash13

[AngelGrinder]

[Mystery]

not that i like saying this but i'm sure some bikers will smash a few bikes up over the winter so you might get one
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Carbon knuckles assure you maximum protect against debris and unfortunate accidents or if someone cuts you off, their side mirror.Mopeds are like chubby chicks.. they are really fun to ride until you're friends catch you on one

[AngelGrinder]

Currently have a vinyl guy working on the design, this is how it's looking currently....


https://i6.photobucket.com/albums/y209/angelgrinder187/Mock_up_1st_Draft1.jpg
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Currently Riding - 2002 Aprilia RSV1000 Mille

[Bishbash]

I love that paint job, hope you get it done! Good luck too.


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My current bikes are - YZF-R1 & GS 500 E

Trackday videos - https://www.youtube.com/user/bishbash13

[Resident Yank]