Topic: Modifying a Windjammer SS fairing

[UnCrash]

I've come to terms with the fact that I like my Windjammer fairing, just not when I'm looking at it from the front. 

When I'm on the highway and going the distance it's the best.  I also really love the storage.   I can put rain pants, cargo netting, lunch, suntan lotion, tools, and the odd bits that fall off my bike during a ride in the "glove compartments".

To live with the fairing I want to "modernize" it by lowering it, changing its positioning angle slightly, and to paint it black.  Knowing that as I hack away at it for clearance purposes I reduce its integrity I emailed Craig Vetter for suggestions.

Here's a copy of my email to him in hopes that the many experts on this forum may be able to share an opinion that they may have.

Hi Craig,
 
I purchased a 78 Honda CB750 SuperSport this December from under a snowpile in Maine and have it running in top form now.  Many folks are turning their old CB's into cafe's.  Mine came with a Windjammer SS, and I was originally going to part with it in hopes of finding a Rickman style fairing for it.
 
After more than 2,000 miles on the bike this summer, I'm convinced to keep the Windjammer.  I love the protection, and the storage that it offers.  I would like to lower it though.  Many current sport bikes have fairings which mount to the body and sit much lower and closer to the front tire.  I would like to modify the brackets and the fairing itself so that I can echo this look.
 
I'm quite handy and am not afraid of a challenge.  I'm also looking at picking up another Windjammer SS to practice on to make sure I get the desired end result.
 
What I would like to do is cut away part of the bottom where it will end up touching the cylinder heads, additionally  I will cut away a little below the headlight, making more room for the top of the fender.
 
My questions are:
 
Will this cutting substantially alter the internal strength of the fairing to a fatal degree?
What substance is the fairing made out of?
How can I bond new substance (fiberglass, epoxy, etc)? 
Should I reinforce the fairing an any additional way because of these changes?
 
I know basic fiberglassing and boatbuilding techniques.   I have this vision which has some unique qualities to it and would love any input that you have.
 
Many thanks,
 
Ben Duffy

Here's a picture of the bike for reference:

[pddpimp]

Too bad you didn't live closer to MN. I have a black one with iron cross speakers and its mint. I'd give it to you for free.

[medic09]

What did Mr. Vetter say?

[UnCrash]

  Wow,

After Medic asked what Mr Vetter said I went and checked my inbox and lo and behold, Craig emailed me right back.

Morning Ben: Your fairing is made of ABS.  To bond you need the stuff
that comes in our repair kit.  NOTHING ELSE BONDS TO ABS It is
original formulation adhesive with scraps of ABS to help repair. If
you proceed, I will make up a special kit with the plastic shapes you
will probably use.



If you want a fairing to modify get an original Windjammer, made
between 1971 and 3.  They were fiberglass.

Regarding mods:  First, I like guys like you.  Take a chance.  Follow
a dream.

The Windjammer is a monocoque design which means the structure is in
the shell.

If you cut it away, you must add the piece of shell back in.  May I
make a suggestion?  Changing the hardware and cutting the fairing is
drastic.  Consider this:  Lower the seat and cut down the top of the
windshield.

Notice Harley's Batwing fairing at the bottom of this page:

http://www.craigvetter.com/pages/Vetter_Fairings/Liberator.html

Same design of 1964.  But over the years,  the seat is lower.  The
fairing is RAISED.  The windshield is cropped to a slicer of what it
was. It all provides pretty much the same protection.

Keep me posted on what you do and I will show pics on my web page.

That's just the best. 

I'm inclined to take him up on his special shape repair kit offer.  ABS is pretty strong stuff.  I may leave it just high enough so that I can clear the front fender, meaning I would only have to cut and repair the bottom ends that will hit the engine head.  I think that this could be done in a clean enough way that I could mock up the needed repair shapes for Craig.

[Lumbee]

...very cool that CV actually wrote you back!  Your taking on quite a project, and u'r smart to get another faring to practice on.  I have a metal working background (opposed to your fiberglass plastic), and I'd approach the project by leaving the faring intact, and left thinking about modifying the mounts to get the desired look.  The faring sits up pretty high on the bike, and there is plenty of room under the headlight for the faring to be lowered closer to the front wheel/fender.  Craig made a good suggestion in also thinking about possible lowering the seat to give the look/feel you desire.  I've looked at the new HD roadglides, and thought I'd like to do a 750 chop with a vetter faring...

[UnCrash]

I should have also clarified that my goal is for a Vettered kind of cafe.

Lowering the fairing will allow me to get drag bars on there, or at the very least the shorter "superbike" bars.

I agree, modding the mounts is first, getting the fairing as low as I would like will have the bottom ends of it contacting the cylinder head, so I need a little clearance there.   I don't think I will have to cut much away after all, especially if I change the angle of the fairing as it sits.

If you notice in my picture the bottom of the fairing is angled nearly 10 degrees from a horizontal level.  I'll have the mount modified so that the bottom of the fairing is level.

I know that this will reduce my wind protection, but that's a sacrifice I'm willing to make.

Additionally I do plan on making my own cafe styled single seat over the winter.

Another reason that I would like to keep this fairing vs going with an earlier vetter for this mod, is that I kinda like the shape and those huge blinker/marker lights.  Yes, I am crazy.

[medic09]

Nice.  A gracious, helpful reply from the man himself!

Good luck with the mods!

[ken736cc]

Vetter Mystery ship, based on Kawasaki 1000

http://www.bayarearidersforum.com/forums/images/threads/000/112/357/1635880-mystery_ship_1980.jpg

[Rhonda750F]

I'm not a vetter fan but I'd take that mystery fairing.  Looks kinda R1-ish, in an 80's edgy kind of way.

[eldar]

Hey crash, I like the vetters too. I got an edge repair kit for mine as the PO decided to drink one night and lay the bike over.  When I got my bike, the front fender had a big dent from 1 side to the other. It was caused by the fairing hitting it hard. Could have been done when laid over or who knows what other stupid stunt the PO did.

I am just saying that if you lower it, you might want to cut some out of the bottom area over the fender to maintain clearance.

[UnCrash]

I am just saying that if you lower it, you might want to cut some out of the bottom area over the fender to maintain clearance.

I was thinking this originally as well, but now worry that it would really degrade the integrity of the fairing.

Any one know a good trick for measuring total fork travel?

[upperlake04]

You could put a zip tie around a fork tube just above the dust seal, then go out and thrash it over the bumps.

[S-Dog]

That fairing is WAAAAAAY cool... When you were packing for our trip up to Owl's head, it looked like a scene out of the circus when the clowns pile into that little car.  You had SOOOO much stuff in it... I also think that a cafe hybrid with the fairing could be quite edgy...

[andy750]

Damn Scott I now have images of clowns and little cars fixed in my brain!! 

cheers
Andy

[UnCrash]

You could put a zip tie around a fork tube just above the dust seal, then go out and thrash it over the bumps.

Brilliant idea!

it looked like a scene out of the circus when the clowns pile into that little car.

  Ya, you gave me a look when I went to put that lens in there like -- "there's no way that will fit"

Why do you think those fairings are so big?    So you can forget about the saddlebags   

[eldar]

Well the bottom is built pretty heavy. You could whack off some of the bottom and put in a some scrap ABS and glue it.  Vetter sells a glue called Hotcha. It seems to work pretty well BUT it takes some time to set. Remember how model cars had to be glued? You put the glue on and hold the part as the glue basically melts and welds the plastic together. Kinda the same thing here.

[UnCrash]

Eldar,

I was figuring I would have to make some kind of jig for the fairing so that I could apply the patch pieces and apply pressure while they and the glue fuse up and cure.

I don't pick easy projects...

[eldar]

It will depend on how much you take off too. The bottom is pretty think, at least on mine. It might not be so bad if they were not so heavy! Took mine off after having it on for a few years and I'm not sure I will ever put it back on! Yet I would like a wind screen.

[Lumbee]

...looking at the vetter web page is got me wanting a faring like this:

http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&sspagename=ADME%3AB%3ASS%3AUS%3A1&viewitem=&item=290155388531

..def got that HD roadglide look/feel...

[eldar]

It certainly changes the bike. The fairing will slow steering and make the forks dive more on bumbs and braking but not overly bad. But it is amazing the difference when riding a long ways or in cold weather. Then a fairing is like a gift from the gods.

[UnCrash]

Fairings do have their minuses, but at highway speed they not only add protection but act as a wing putting some downforce on the front end which adds stability.

Craig emailed again with a picture of a modified 2 headlight ABS Windjammer:

Just fine to post my responses.  By the way, I meant to say "sliver of a windshield."


Keep me posted on what you do.  Here is a sample of what you can do with ABS mods:





It was the test bike for the twin headlights we used on our Liberator fairing on 1973. That is Charly Perethian who is now the man at Parabellum.


Craig

If they were able to modify the ABS to allow two headlights without structural degradation then I'm in good shape with my planned modifications 



Here's my response to him:

Hi Craig,
 
I'm only encouraged by your responses.  I'll try to get some garage time in this weekend when my 1 year old is napping to mark out my cuts and maybe even paper template insert/replacement pieces.  I'll show you the details in hopes of your opinion on the viability of my plans with the ABS fairing.
 
- All the best.
 
 
Ben

[purveyor]

Way to go on your idea.
I have a Vetter on my 78 750 f2.
Can crack off 120mph. A little simmy coco puff at that speed so I am looking into a fork brace to put on this winter. I have stiffer springs in the fork and she still dives if you use too much front brake.
Storage,stereo,wind break. I have a tough time not taking her every place.
My 73 500/4 only goes to the pub and some local cruses now.
No more long trips on the 500.I used to take her on 5-6 hour tours.80 mph all day long.
best of luck

[eldar]

It is really cool that Craig still gets into this.  Dont be afraid of the ABS. It is tough to work with yet can be very forgiving as it is so strong. I look forward to seeing what you dream up!

[UnCrash]

This morning I pulled the fairing and its bracket.  Using a couple flower pots I elevated the fairing to my approximate desired height.  I still need to confirm overall fork travel, though I know that I would like to make the forks a little stiffer than they currently are.

Here are some pictures:







It looks like I'll need to trim the back edge where the fairing is resting on the sparkplug wires    aside from that the rate of fork travel will help me determine if I need to cut away under the headlight at all.

Doing this modification will allow me to put on Euro bars...  I hope to get a pair of rearsets on her over the winter as well as caffenating the rear end.

Cheers,

Ben

[jtb]

Ben, I haven't cleaned the marks off of my fork tubes since the last outing.  Max travel last ride was 2.5"   I've got Progressive springs in them, and suspect max travel would not be greater than 3".  It looks like you should be OK.