Topic: Anyone ever make a foam mold and a 1-off FRP of the acursed side cover?

[dboblet]

OK, I give up.  Short of a miracle, I seriously doubt I can find an affordable side cover for my '78 CB750F SS.  So.... I'm going to make a foam model and create a fiberglass cover of my own.  Question is, has anyone done it and if so... how hard is it to make the pins that go to the grommets?  I figure the cost of making a set will be around $30 US for all materials and supplies....  It probably won't look as nice as a stock cover, but beats the heck out of all those wires and connectors hanging out in the wind and rain.

[mkramer1121]

There's a place in England that makes nice knockoffs.  They're ABS, and will run you around $75 USD for a pair.  Worth it when you consider good used ones are around $30 each.

[Vtec-Sauce]

There's a place in England that makes nice knockoffs.  They're ABS, and will run you around $75 USD for a pair.  Worth it when you consider good used ones are around $30 each.

Nice!, ill call "a place in england" in the morning...

[Geeto67]

There's a place in England that makes nice knockoffs.  They're ABS, and will run you around $75 USD for a pair.  Worth it when you consider good used ones are around $30 each.

$30? try $100 for the left and $30-$50 for the right for used originals.

I thought about making a mold off my originals because then we could have the sidecovers made in carbon fiber.

If you are making the buck (the thing you use to make the mold for the sidecovers) by hand and not using an original side cover, then I imagine it would be very difficult to make an accurate side cover (hence why the crappy repros have screws and not the factory pins).

I have seen a pair of the repros and they are nice and while pricey they are worth it. check the other post about '78 F side covers (the one that got lost) and there is a link to "a place in england"

...smart ass

[super pasty white guy]

http://lpmreplicaparts.com/

[dboblet]

or more specifically:
http://lpmreplicaparts.com/honda/CB750F2/sidep.html
for side covers for the F2

The price translates as abut $52 US EACH.
out of my budget.

[dboblet]

But back on topic, I'm interested in people's experience and what I should look out for when I try this.  I'm no novice to frp, having had a fiberglass cruising boat a few years back, but fab'ing from scratch using foam rings more like making foam core surfboards than doing hull repairs.  Advice?

[mystic_1]

Off the cuff, and with the caveat that I've not done any real fiberglass work before, it may be easiest to create the pins separately first, then mold them into the side panel when you lay the glass for that.

If you have any existing side panel with an intact pin you could probably pull a silicone mold off of that, cast a positive out of plaster, then make a two-part fiberglass mold for casting your pins.

Google around on this topic, I've seen some very nice fiberglass and carbon fiber projects similar to this on the web.

Also, if you decide to proceed with this, definitely share your results, good or bad! 

mystic_1

[Geeto67]

if you are not hung up on originality - most of the drag bikes I have seen (including a few of my own bracket race bikes) used sheet aluminum.

We would just cut a flat piece to fit in the rails then get a couple of bolts with a wing nuts and a stack of washers (or you could make your own spacers out of bar stock. Looked badass, weighed nothing, covered the electrics - what more could you want.  Make sure to put the wingnuts facing out on the bike so that you can remove the covers easier. I imagine dzuz fastners would work as well.

Honestly the only difference between the 75-76 left side cover and the 77-78 left side cover is the mounting tab and its spacing so I doubt you will have any luck getting those tabs off another bike.

[bryanj]

Fiberglass too inflexible and will crack/shatter.

The lpm repros are made from a more pliable plastic than the originals----30 yrs of improvements in materials-- and damn good quality too

[bradweingartner]

I don't remember where I saw it. Or when.

What I do remember, is that it was a technique for adding a carbon fibre weave to the outside of existing sidecovers. But I'll explain my vision.

What they did, was vacuum bag it. And it looked damn easy actually. Layed up the carbon fibre over the side cover with resin, bagged it, vacuumed it with a shop vac and Viola! A few coats of finishing resin and some elbow grease later, he had a completely blinging carbon fiber overlay for his side cover.

Now I say, instead of using the side cover you DON'T have. Make and finish a foam plug, and just form around it. Rather than making a concave mold. Saves a big step making the mold. The bag naturally leaves some bag marks in the resin that will need to be sanded out and finish-resin top coated, but I think it's still easier than the full mold process. This is coming from someone who has done very little traditional fiberglass work!

I wish I could find the website :-(

[bradweingartner]

UPDATE!

http://www.webbikeworld.com/t2/carbon-fiber-motorcycle-parts/

Check this out for some neat information.

Doesn't help with the stock pins. I can't even fathom how I'd do that myself to be honest. But I think something could be bonded to the inside post-molding without too much hassle.

[FunJimmy]

I'm no expert at making fiberglass/carbon parts but I have made a front and rear carbon fender patterned from a Suzuki GS750 for my CB550 project bike.
I personally would make a finished plug from a damaged side cover and then build the negative mold. The results will be better, lighter and stronger than the lay over method.
Furthermore, you will have the mold to reproduce you efforts as often as needed. Can you say “return on investment”!

As for pins. You could probably use acrylic rod and turn the head on a lathe to fit snugly in the grommets. Round stock should work fine. Once you have the rod/pins, they can be bonded inside the covers with epoxy putty.

This guy makes it look easy. http://www.bayarearidersforum.com/forums/showthread.php?threadid=145975

Good luck
FunJimmy

[mystic_1]

This guy makes it look easy. http://www.bayarearidersforum.com/forums/showthread.php?threadid=145975

Seen that thread before, it's a good one.

mystic_1

[andy750]

I have seen a pair of the repros and they are nice and while pricey they are worth it. check the other post about '78 F side covers (the one that got lost) and there is a link to "a place in england"

...smart ass

$56 per cover - not incl shipping and will save you many hours of work 

http://lpmreplicaparts.com/honda/CB750F1/sidep.html

[bradweingartner]

That thread is great, really inspriational.. I'm going to compile everything the guy showed in that into a single How-To. I think a lot of people could benefit from that without having to deal with all the small-talk!