Front Cowl

The New front fairing i have chosen for the bike will be as mentioned before a CBR600rr 03-04 model. I managed to pick up a front cowl on ebay dirt cheap. thos its slightly damaged and the wrong colour... to work we go.

So looking at the left side of the fairing, there is damage all around the indicator locator:

using a heat gun the decals were removed

a little wd40 to clear all the glue residue off work perfectly

so looking at the damage, figuring out what best to be done...
i pilot drilled all the ends of the hairline crack to stop them spreading, and decided to just cut out the majority of the damage as i dont require the indicator locators for my vision.

Damage cut out

Fibreglass repair

area sanded out

Filler and more sanding

filler primer to show any defects and more filling and sanding

wet and dry sand down, right side complete

left side (no damage)

Indicator locator to be sanded right down.

filler to make it all even and smooth

again filler primer to pick out defects

more filler and filler primer till desired finish is achieved

primer coat

Top Coat (lacquering will be done later)

Front Subframe

Hi all, sorry there hasn't been many posts lately. The plan was to have the bike finished this summer, but from falling pretty ill, making many visits to the hospital, and being told not to lift anything remotely heavy, all kept me away from the bike :( I did however manage to get a few more mods completed.

The new look for the bike proposes a new front cowl and headlight, both to which need to be mounted to a front subframe. The vfr front subframe wont support the new additions so a frame needs be created.

Mindful considerations for the build are that it needs to have a mounting point for the new headlight, new front cowl, current relays/sensors/instrument panel, and also allow for complete uninhibited movement of the cbr1000rr front end.

The way i went about making the part was to go step by step, allowing one aspect to fit/work, then adjusting/re-modding it to make another aspect fit/work, and so on...

So first i worked with the current subframe trying to fit it to the frame and allowing full movement on the front end. As the fireblade has much lower down handle bars, there was a problem with the front brake&clutch lever making contact with the instrument cluster, and full lock couldnt be achieved. And so the the front subframe needed to be extended out. Simple solution was to make a bracket...

simple card mock 

plastic mocks to attach

fitted, checking positioning

final design draft

Brackets made :)

Standard vfr front subframe:

Frame built to support instrument panel, relays, bank angle sensor, and brackets to frame:

Brackets to attached to frame bolted on:

Brackets to mount front cowl and wing mirrors made:

Finished: