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Fitting aftermarket fibreglass fairings to VFR750 *UPDATED*

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stinkwheel
Bovine Proctologist



Joined: 12 Jul 2004
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PostPosted: 17:38 - 13 Jul 2013    Post subject: Fitting aftermarket fibreglass fairings to VFR750 *UPDATED* Reply with quote
So. My second generation VFR750 lost a large lump of fairing between leaving the MOT and getting home.
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/CIMG0998_zps65342636.jpg

Given that they are like rocking horse poo and that there wasn'rt a single panel on the fairing undamaged, I decided to have one more attempt to get a replacement fairing.

I eventually came up with a place called Poly 26 in France whi make fibereglas fairing kits for pretty much everything. The however refuse point blank to speak or use any language other than French and will only communicate by phone or post. So pretty much a nightmare. I eventually found a place in Darlington called Adrenalin-moto who act as their dealers in England.

Ten days and £320 later my fairing kit arrived.
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1010_zps616da97e.jpg

They have done in three pieces of fibreglass, what honda did in more than ten. It's a very authentic looking replica too.

They do seem very sturdy too, good and heavy duty with a healthy overlap where they join together for the fastners of your choice.
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1011_zpsf0b6414d.jpg
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1012_zps6e713672.jpg
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1013_zpsa1c8b980.jpg

I've seen some pretty shoddy race fairings in my time but this is a whole different class, they are thick, well finished and reinforced with extra glass where it needs it on stress points and fitting lugs.

SImply offering the parts up to fit shows you how well these have been done.
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1041_zps2d72ca0d.jpg
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1040_zps30ffd32d.jpg
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1039_zps5fc171b8.jpg

So. Fit for purpose. Thumbs Up
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

Last edited by stinkwheel on 15:06 - 27 Apr 2014; edited 1 time in total
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stinkwheel
Bovine Proctologist



Joined: 12 Jul 2004
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PostPosted: 17:50 - 13 Jul 2013    Post subject: Reply with quote
The main hurdle here is that they have no internal fittings to attach things like headlights, and flashers. All the holes to attach them to the bike and one another will be to drill myself.

First hurdle to overcome is the headlight. On the standard bike, it attached to four lugs built onto the inside of the top fairing.
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1029_zpse818a274.jpg

I don't have any on the new ones.
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1030_zpsf4cfb7c8.jpg

After some deliberation, I decided to mount the headlight on the front subframe instead of trying to bond lugs onto the new fairing. So set it for position using cable ties (it engages with a couple of rubber pegs at the back). I'm using the worst of my two lights here. I have one with all the mounting lugs intact instead of glued on alloy plate which I'm keeping for a spare for reasons which will become obvious.
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1032_zpsbfc446eb.jpg

I spy with my little eye, a (now) redundant lug with a captive nut attached on the front subframe.
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1045_zpsb764c0c5.jpg

So we need a couple of brackets making up out of that bit of stainless angle I have lying around.
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1046_zpscea524f4.jpg

Now attach them to the headlamp shell by the power of hot glue gun and pop rivetts and fix the whole lot in place. NB using stainless rivetts. Never use alloy rivetts in stainless because of galvanic corrosion.
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1047_zps32e2e119.jpg
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1048_zpscb44927c.jpg

More solid than it was before and with a little flex from the rubber bushes. Offering the fairing up shows a few gaps round the cutout but they had a few even on the original which is what all that black foam stuck the the headlamp unit is in aid of.
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1033_zpsd4d76ed2.jpg
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.
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stinkwheel
Bovine Proctologist



Joined: 12 Jul 2004
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PostPosted: 18:02 - 13 Jul 2013    Post subject: Reply with quote
Next job is getting the plastics loosely attached in roughly the correct position so the rest of the fittings can be measured and drilled as appropriate.

For the holes I'm using a step-drill. I may make some of the more load-bearing holes bigger later and use a rubber grommett in them to take some of the starin off the fibreglass itself. With a step drill, you can make them as big as you want.
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1034_zps95255062.jpg

The top fairing has two holes that attach to the front subframe over the mirror mounts. These can't really go anywhere other than that one place so a good starting point.
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1035_zps0bb0788f.jpg
The screen then kind of pulls it all into alignment.
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1036_zps2c58a6d1.jpg

Once that's on, it gives me the location for the two side bolts (I've got some nice stainless ones squirrelled away for the final assembly). These are rubber mounted anyway so there is a cartain degree of leeway with the fit.
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1042_zps719b8939.jpg
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1043_zps36f5bdab.jpg

Just using the backmost attachment for the bottom plastics, loosely attached then swinging them up into place against the top fairing.
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1037_zpsb682f3a3.jpg
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1038_zps18528903.jpg

So that's the plastics on the bike itself. and they mesh together pretty neatly.

The next job is measuring up and marking out where the remaining fastners are going to go. I'm going to be making extensive use of dzus quarter turn fastners for the rest of the build but I don't have the correct pop-rivetts to hold the backing plates on. This seems like a good place to stop for now.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.
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Frost
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PostPosted: 18:03 - 13 Jul 2013    Post subject: Reply with quote
You could always take the mountings off the original fairings and stick them on using fibreglass?

What colour are you going to paint it? Very Happy
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stinkwheel
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Joined: 12 Jul 2004
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PostPosted: 18:09 - 13 Jul 2013    Post subject: Reply with quote
Frost wrote:
You could always take the mountings off the original fairings and stick them on using fibreglass?

What colour are you going to paint it? Very Happy


I'm going to go to my local accident repair shop and see what he's got lying around. He does a lot of boy racer cars and might have something interesting.

Failing that, probably gloss black or red + or - my choice of vinyl wrap as the mood takes me.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.
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Ed Case
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PostPosted: 23:21 - 13 Jul 2013    Post subject: Reply with quote
As an alternative to the stupidly expensive genuine kit that stuff looks good and at an affordable price (providing you've got a job of course).
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SteveZZR
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PostPosted: 00:58 - 14 Jul 2013    Post subject: Reply with quote
Looks like pretty good quality kit!

Hope you're going to clean up underneath before final fitment!
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stinkwheel
Bovine Proctologist



Joined: 12 Jul 2004
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PostPosted: 09:18 - 14 Jul 2013    Post subject: Reply with quote
SteveZZR wrote:
Looks like pretty good quality kit!

Hope you're going to clean up underneath before final fitment!


Meh. It's just oily muck. That's pretty much as clean as it gets. I even repainted the engine sidecovers lat year. I'll give it all a good spray over with ACF 50 before I fit them the last time.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.
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SteveZZR
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PostPosted: 09:32 - 14 Jul 2013    Post subject: Reply with quote
stinkwheel wrote:
SteveZZR wrote:
Looks like pretty good quality kit!

Hope you're going to clean up underneath before final fitment!


Meh. It's just oily muck. That's pretty much as clean as it gets. I even repainted the engine sidecovers lat year. I'll give it all a good spray over with ACF 50 before I fit them the last time.


You sound as bad as me! Never tend to clean my bikes really even though I really should. Just using a bit of ACF50 would be a start Razz
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MarJay
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PostPosted: 12:32 - 15 Jul 2013    Post subject: Reply with quote
Adrenaline Moto are great guys, I've had a few dealings with them, they are Buell specialists and they also run a site specialising in V twins called Twinshack. I know about the french company, they make awesome looking cafe racer fairings too.
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Remember kids, bikes aren't like lego. You can't easily take a part from one bike and then fit it to another.
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Moxey
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PostPosted: 14:26 - 15 Jul 2013    Post subject: Reply with quote
Good to know Thumbs Up though mine are in fairly good nick at present, still could be useful in the future especially as Darlington is 10 mile away from me.
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stinkwheel
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PostPosted: 14:44 - 15 Jul 2013    Post subject: Reply with quote
Ok. So they fit. They now need to be held on and together.

Pretty much an eyeball job, Once I decided how many fittings each piece would need, I measured them so they were spaced evenly and at a point where they will catch both pieces without fouling anything underneath.
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1049_zps43986006.jpg

Once the top piece is marked and drilled, offer it up and mark then drill the bottom piece for pilot holes.
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1050_zps05b8f98a.jpg

I've splurged and bought Dzus fastners for this job because they are easy to fit and remove, are somewhat forgiving with positioning, don't excessively load the plastics and can't undo themselves. They also look the business.

I'm using rivett-on base-plates, you also get clip-on ones.
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1054_zpsc1385bc7.jpg

There is a right way and a wrong way to go about this. It's easy to get the holes in the wrong place so drill out the big hole in the middle firstusing a holesaw and offer up one of the backing plates. Use this to drill the first rivett hole and rivett it in place:
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1059_zps258bd168.jpg
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1060_zps9fe4dabe.jpg
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1061_zps197fa152.jpg

THEN do your second hole:
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1062_zps8a5f3b2f.jpg
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1064_zpscae523fa.jpg
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1063_zpsd2b85d3c.jpg

Rinse and repeat:
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1056_zps67c1ec77.jpg
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1065_zpsbe883511.jpg

Then it's just a case of drilling the outer holes to the correct size and inserting the "male" part of the fastner. 1/4 turn and it's all locked in place with the fastners aligned in a neat row. The male part will eventually be fixed in place on the plastic between two thin plastic washers so they can't drop out when removed but I've held off this until after it's painted.

https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1066_zps7a65130b.jpg
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1067_zps9d751c41.jpg
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1068_zps7ffbe694.jpg

Now that they're on, next job flashers.

Also as a footnote, I'd really advise wearing long sleeves and gloves for this job. My hands and forearms are REALLY itchy from drilling all that fibreglass.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.
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groovylee
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PostPosted: 17:01 - 15 Jul 2013    Post subject: Reply with quote
Nice job mate, you are really inspiring me into doing something with my fairings on the GPshed. I like the look of the fasteners too, I will have to have a look at them for mine Thumbs Up

Lee
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Ed Case
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PostPosted: 20:19 - 15 Jul 2013    Post subject: Reply with quote
Niiiiice !.
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stinkwheel
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Joined: 12 Jul 2004
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PostPosted: 12:23 - 16 Jul 2013    Post subject: Reply with quote
Flashers. This has proven to be the trickiest bit so far.

Measuring up the original and the new fairing shows the thin line in the gelcoat exactly matched up with the size the hole needs to be which saves me a fair bit of marking out.
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1069_zps9f9b4034.jpg
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1070_zpsaefb2229.jpg

A junior hacksaw turned out to be the most useful tool for cutting the hole out. I think a small cutting disc on a pneumatic whizzer would have made it easier but I always try to remember that power tools can get you into trouble a lot quicker than hand tools:
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1071_zps3ed34134.jpg

After a lot of cutting, some with just the blade and a fair amount of filing, I finally got the hole the right shape to fit the flasher in. There's a bit of a gap at one point but it'll be perfectly possible to fill this in later on. On the whole a pretty good first attempt, I did a better job with the second one.
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1074_zps229dd4fd.jpg
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1073_zps90101909.jpg
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1075_zpsec9ba2db.jpg

Next job is going to be making a bracket to fix the flasher in place (although it's a pretty good fit anyway). I've had some thoughts on this subject so meansure how tall it needs to be:
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1076_zpsec5a19ab.jpg
Next I got some aluminium tubing with a 4mm ID and cut a section of that and a piece of 2mm aluminium plate so they make up that height when stacked on top of one another:
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1077_zps825d837f.jpg

Pop rivett them together:
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1078_zps89347b5b.jpg

Can you tell what it is yet? Marking out the position the bottom plate needs to sit at on the panel.
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1079_zps1ac2258b.jpg

Now the fuel tap which sits recessed into the fairing:
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1080_zps9ce75aa0.jpg

One bolt goes right through (and onto a bracket on the front subframe eventually):
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1081_zpsc45da63a.jpg

It also attaches to the inside of the fairing with three screws:
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1082_zpsf459abc8.jpg

So having made a cardboard template, bend up a plate and mark out the hole centres:
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1083_zpsa1d9cef8.jpg

Repeat the trick with the aluminium tube:
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1085_zps0da42aba.jpg
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1086_zps703f033f.jpg

Nice:
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1084_zpsa9d8c3ed.jpg

Now to bond them in place. Note use of gaffa tape "dams" to stop the epoxy flowing away from the bracket before it's set:
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1087_zps31fd1db9.jpg
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1088_zps4ceb5d1d.jpg
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1089_zps526253d6.jpg

Instead of screws, I'm going to pop-rivett the flashers and fuel tap to the brackets. It'll be strong and secure and takes a matter of seconds to drill/file/burr the heads off the rivetts if they need removing in future.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.
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SteveZZR
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PostPosted: 22:07 - 16 Jul 2013    Post subject: Reply with quote
Looking good!

The beauty of fibreglass is that it can be filled, repaired and reinforced really easily.

Might be worth getting some Mastik bodyfiller for any additional holes / etc you don't need (or any gap around the indicators)


When I fitted my ZX6R fairing to my ZZR 600 I had some holes I'd drilled just to temporarily hold the fairing on the bike whilst I was making my custom bracket; I've since filled the holes with Mastik and you can't tell they were ever there now!
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stinkwheel
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PostPosted: 15:39 - 18 Jul 2013    Post subject: Reply with quote
Right. That's them on and ready for some epic road testing this weekend. Then I can fill any odd bits and start thinking of a colour.

Maybe get a high-level mid-section bent up for my micron can while the plastics are away being painted. Maybe a dyno run too?
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1096_zps62f1eede.jpg
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1097_zps6a16152d.jpg
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1095_zps9e8649ca.jpg
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1098_zpse53baa4f.jpg
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.
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Musketeer
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PostPosted: 16:07 - 18 Jul 2013    Post subject: Reply with quote
Nice job Thumbs Up

It looks like so much hassle though. I would hate to fiddle with fibreglass myself, it's so easy to crack it.

I've got a fibreglass tail tidy in my shed and cannot be bothered to fit it Wink
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pepperami
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PostPosted: 20:23 - 18 Jul 2013    Post subject: Reply with quote
Impressed Thumbs Up
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fatjames
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PostPosted: 16:53 - 19 Jul 2013    Post subject: Reply with quote
Very nice mate. Good work
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panton438
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PostPosted: 21:23 - 19 Jul 2013    Post subject: Nice Reply with quote
I would quit after like 30 minutes...
Bike looks good!
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stinkwheel
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Joined: 12 Jul 2004
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PostPosted: 15:06 - 27 Apr 2014    Post subject: Reply with quote
FINALLY got my shit together.

Sourced a non-dented tank off ebay which had been done with some horriffic rattle-can paint that didn't even blister with my nitromorse, it went into a sort of gloop that needed to be scraped off.

Put the whole lot into a local bodywork repair spot with instructions to make it matt black all over. He was a little uncertain about this but when I came to pick them up his comment was:
"I thought you were mad getting brand new plastics painted matt black but that top fairings been sat in the corner of the workshop for the last few days staring at me. It's pretty menacing.".
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1604_zps14b8a522.jpg
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1607_zps029b660f.jpg
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1610_zps4f9ecba6.jpg
https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1608_zpseeaca721.jpg

It turns out, they make black silicone sealant. I've filled in the gaps round flashers etc using that. Dual purpose because it'll cut down on vibration as well as being easily removed as required.

Need to keep an eye out for a tailpiece now. Poly26 do one but I'm not sure if I can really justify the cost. Maybe next winter. it needs riding now.

I've made a "tank pad" using some leftover vinmyl wrap to prevent my zip/belt buckle damaging the paint. Blends in nicely so you can hardly see it.

You'll notice the micron can is fitted. Local exhaust guy said it would be a total ball-ache to bend up a high level pipe but a piece of piss to make me a link pipe with slip-joints so I just need to undo the hanger bolt then pull it off to one side to change the wheel. £60 for the mid section. Need to give to a clean up now.

https://i48.photobucket.com/albums/f216/stinkwheel/VFR/1CIMG1609_zpsda68b80f.jpg

Three things I still want to do are 1) Powdercoat the rear wheel because it's tatty as hell. 2) Fit some different mirrors, those rubber covers on the mirror stalks never did fit properly. I think the early VFR800 ones might fit. 3) Fit a black, double-bubble screen.
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“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.
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Moxey
World Chat Champion



Joined: 11 May 2011
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PostPosted: 20:55 - 27 Apr 2014    Post subject: Reply with quote
Looking good fella, after the cost it came to for two replacement tail fairings on mine, I would definitely consider getting some brand new ones made up like how you have.

Out of curiosity what happened to the old 4th Gen you had? Found the thread on here when I was looking for advice for the VTR front end swap and was just curious what became of it.
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stinkwheel
Bovine Proctologist



Joined: 12 Jul 2004
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PostPosted: 21:32 - 27 Apr 2014    Post subject: Reply with quote
Moxey wrote:

Out of curiosity what happened to the old 4th Gen you had? Found the thread on here when I was looking for advice for the VTR front end swap and was just curious what became of it.


Too many winter runs over the A66. It was rotting away under me.

I went to go away on it one weekend and had three seperte breakdowns, each involving a different part of the bike and decided enough was enough.

There are enough parts in common for it to make a good source of spares. Although said chronic rot and repeated minor crashes mean even if the bodywork did fit (which it doesn't), it was all smashed to bits anyway.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.
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Old Thread Alert!

The last post was made 11 years, 119 days ago. Instead of replying here, would creating a new thread be more useful?
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