headlight mounting to fairing frame ?

[phuk72]

Phew, glad it's not just me.
Kextrx849 is your light the single unit with twin lamps inside ?
Keep getting bull-nosed shark when I look at the last one ? No offence. (leathers are an excellent fit BTW )
Looks like a lot of work guys, don't the fairings get a bit heavy with all the extra fibreglass added ?
I will post some more pictures of my progress (as long as they're not boring folks to death ?) but this might all need moving to the "mods & upgrades" section then ?

yes - they are shark eye spots (and glad leathers fit ok)

my fairing still weighs half that of the original

[Kevtrx849]

Kextrx849 is your light the single unit with twin lamps inside ?
Looks like a lot of work guys, don't the fairings get a bit heavy with all the extra fibreglass added ?

Yeah thats the one, mounts up in the original frame.
I used a raceglass fairing and cut the holes then "frenched" them in. No heavier than the standard unit really.

[G Beale]

Hope this isn't boring everyone but it's all I seem to do lately.
I decided to go for 2 holes ala early EXUP for the simple reason that it seems stronger with a bridge down the centre. Wasn't sure if I would like it but it's growing on me.

Solved the off set frame mount problem by replicating ? duplicating ? copying the bracket with 2 pieces of plate, 1 with 2 nuts welded to it for the frame bolts (out of sight), both with 2 pieces of tube passing through them, both tubes immaculately welded to the FZR frame.

Went a bit OTT with plate width (2.5mm) to be safe which is why I've chopped & drilled as much out of it as I dare.
This is how far off centre the TRX mount is.

I'm making no excuses for my welds, I'm a windscreen fitter by trade so just give me a break would you. They look better in real life honest.
Got some filler to sand now then I might have the frame shot blasted before I paint it.

[Jak]

but this might all need moving to the "mods & upgrades" section then ?

I can move it whenever you want, just let me know.

[steve speed]

welding is not bad but if you want it a bit better try turning your wire speed down a bit and the amps up , are you using flux coated wire ? or co2/ argon mix, well done for giving it a go just had another look are you using a stick welder ? or mig

[G Beale]

It's a mig with C02. My bestest welder broke a few months back so I bought this little 105amp thing as a temporary measure but I can't really get to grips with it (as you can see). I will turn the wire speed down a bit but the power setting is a bit crap, last one had a dial with 7-8 settings, this has got 3 switches one with high-low, one with med-min & one with max ? By the time I've sussed it properly it will have been replaced by something with a bit more adjustment & poke hopefully.
PMSL you thought I arc welded it. Is it that bad ?

Jak, if you want to move this to somewhere more suitable (the bin ??) it's fine by me.

[steve speed]

no its not that bad ,, the welds just looked a bit heavy,, what i do is have a bit of a practice on some scrap of the same thickness that i am going to weld and play about the settings until i have a good weld with some good penetration , i have found that co2/argon mix about the best ,, mines a Clarke 135te turbo , i would like to have a go at tig next , its a lot neater but a lot more £££££££££££,, have you got one of those flapy disks that fits in the angle grinder they also make the job look a lot neater

[Kayla]

... somewhere more suitable (the bin ??) it's fine by me.

Bless

The fairing looks really good and it'll really suit the bike when it's done.

[G Beale]

Yeah someone gave me one of those flappy disc things but I've never used it. Think I will just paint it all & forget about it in the hope that we never meet so you can't point out my crappy welding. I had better do a good job of the actual fairing now in an attempt to divert attention away from the fuglyness.

[steve speed]

if you look at some of the welding Yamaha did on the frame you will see its not exactly Rolls Royce ,, give a good belt with a hammer to test the weld then undercoat and black satin and your good to go ,,, looking good so far

[G Beale]

Just as I thought a good ole coat of black & it all looks fine (from 3 mtrs away if you poke yourself in the eye then squint).

I've sanded all the filler now so just need to undercoat & paint the fairing black for the full effect but I must admit I'm well happy with the new look.

Sort of TReXup ?

Wires next so they actually work.

[Tarwetijger]

You are working fast! what material did you use to make the bar between the lights?

[G Beale]

I left the 90 deg' lip from what remained of the old headlight hole and folded some ally mesh over it then plastered car body filler on to that. I have a huge tub of the stuff so it seemed like the right choice. Took a lot of building up & sanding down to get just right but I knew it would. It's very strong, I've been using it as a carry handle when ever I move the fairing.
Earlier pictures show 2 vent shaped cut outs either side of my new light holes which looked a bit odd so I filled them in too.

[G Beale]

It's done !


Had a lot of grief with the paint reacting so had to build it up slowly. Being cellulose it tends to sink after a day or 2 so I've flatted a few marks out here & there. I just used some metalic black I had kicking about from a car bumper I did with cellulose lacquer on top. It's a bit grey compared with the Yamaha paint but not too bad. I got a spare tank to do the same colour soonish so that will just leave the seat unit.

Looks better from some angles than others.

Fitted my standard indicators as I didn't like those carbon copy bullet/teardrop ? things that were on the original fairing.

FZR light wires were roughly half the thickness of the TRX loom wires so I just made a piece that plugs in the TRX bit with 2 of everything coming off it for the 2 lamps. Both have side light bulbs so both lamps are on regardless of setting which is what I wanted.


Went out on it last night without the fairing fitted just to see if the lights would work without melting anything as wires aren't really my thing. They seem ok so that's that.
Might get some stickers to break up the black a bit but other than that I'm fairly pleased with the result. I'm thinking Rossi test bike 2005 Gauloises rep colour scheme might do the trick ?
I know some might think I've ruined or am slowly ruining my bikes appearance but my aim is to replace all the good bodywork with some not so good stuff ready for my Annual trip to the Nurburgring. I normally go in a car but this year will be takin the bike in the back of a transit.
I suppose better brakes should be next on the list.

[gregs656]

I like that, it looks good.

Get some bluuespots on there!