Making your own side covers


Information and questions on GL1000 Goldwings (1975-1979)
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JellyBelly
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Making your own side covers

Postby JellyBelly » Wed May 23, 2012 1:31 pm



So I found this site on making your own carbon fiber bike parts (http://www.webbikeworld.com/t2/carbon-fiber-motorcycle-parts/)

Has anybody attempted this?

I'm not sure I like the carbon fiber look. I was thinking I might make my own fiberglass frame/battery side covers...might even start selling them. :D It's hard to find good quality frame/battery side covers. I might need to go into business doing it because it seems like there are many cracked and patched ones out there.

This seemed like a pretty good demonstration.

First I'll need to make my own mold and go from there (once that is done I'll be in manufacturing mode :D . I probably will reinforce the tabs with aluminum since this seems to be what breaks first.

Has anybody attempted to make their own frame/battery side covers?


Last edited by JellyBelly on Wed May 23, 2012 2:00 pm, edited 3 times in total.
I love my wings (both Hot and Gold) - check out my blog @ http://wingthing1000.blogspot.com/

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Re: Making your own side covers

Postby WingAdmin » Wed May 23, 2012 1:47 pm

You'd probably need a vacuum form to pull ABS into the compound shape of a side cover. Fiberglass would be easier to work with, although not nearly as fast as you could pump out ABS covers (if you had the technique down).

I wonder if it would be possible to sculpt both a positive and negative mold for a cover, so that a hot sheet of ABS could be pressed between them? The posts would have to be added after the fact. I wonder what the molds could be made of, to make them resistant to heat, yet sturdy enough for multiple use?

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JellyBelly
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Re: Making your own side covers

Postby JellyBelly » Wed May 23, 2012 3:04 pm

So I'm planning on vacuum forming the side covers to make my mold...and then making fiberglass side covers...that's the plan.



- shows how to make the vacuum forming machine..



- shows making a pretty cool helmet.

Now if I could just get the time... :-)

I need to make some new covers for my '78...mine are cracked.
I need to buy some left and right covers to make molds from for my '77...anybody have any for cheap?
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Fred Camper
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Re: Making your own side covers

Postby Fred Camper » Wed May 23, 2012 4:06 pm

There is a thread on WWW.NGWClub.com where a tail section, shelter covers and side covers are done in carbon fiber. He demonstrates the technique well.

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JellyBelly
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Re: Making your own side covers

Postby JellyBelly » Wed May 23, 2012 4:58 pm

Do you know the specific link...I couldn't seem to find it.
I love my wings (both Hot and Gold) - check out my blog @ http://wingthing1000.blogspot.com/

Former 76, 77, and 78 GL1000 owner...Upgraded to a Chromed out Valkyrie

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Fred Camper
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Re: Making your own side covers

Postby Fred Camper » Wed May 23, 2012 8:46 pm


RexAubrey
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Re: Making your own side covers

Postby RexAubrey » Thu May 24, 2012 8:59 am

Making a form is not that hard and not that expensive if you have one set of covers to make the form from.

Plaster of Paris reinforced with fiberglass fibers works well and is heat resistant. Take a deep pan or box and mix your plaster and fiberglass and fill the pan or box about 2/3rds to 4/5ths full then press the convex side of the side cover into it (use a sheet of plastic wrap to keep the side cover from sticking to the plaster). once that is set up remove the side cover and use fine sand paper to smooth out the form if needed. to make the form for the inside you would place the cover in the pan or box first then pour the plaster mixture in and let it set. remember to agitate the pan or box when you first pour the plaster mixture to remove the air bubbles and give you a smooth finish. you can fill any imperfections with more plaster mixture or use bondo.

remember to use a releasing agent when making your covers and if you want to use ABS you can put the entire thing into the oven to soften the ABS and let the weight of the Plaster press the form out for you. If it is too light you can put a rock or brick on top of the form to add pressure.
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JellyBelly
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Re: Making your own side covers

Postby JellyBelly » Thu May 24, 2012 9:56 am

So I think I may make a mold using the vacuum technique and go with carbon fiber...but not just any carbon fiber. Look at these colors...I'm thinking Red..to go with my red seat I just made. I may just have to carbon fiber everything :D I'm going to be dreaming about this tonight :lol:

Scrap that idea...they want $90 for a 40" sheet
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Former 76, 77, and 78 GL1000 owner...Upgraded to a Chromed out Valkyrie

hrc1966
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Re: Making your own side covers

Postby hrc1966 » Sun Jul 29, 2012 6:21 pm

I started making Gl1200 left side covers a couple of weeks ago.. First one sold..

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Re: Making your own side covers

Postby wdwillis » Sun Mar 31, 2013 8:25 pm

do those 1200's fit the gl1000?

can't even find a garbage one on ebay
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Re: Making your own side covers

Postby hrc1966 » Mon Apr 01, 2013 3:22 am

wdwillis wrote:do those 1200's fit the gl1000?

can't even find a garbage one on ebay



[quote="hrc1966"]I started making Gl1200 left side covers a couple of weeks ago.. First one sold..[/quote]


I have stopped making them, as there is no real market for them..

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wdwillis
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Re: Making your own side covers

Postby wdwillis » Mon Apr 01, 2013 4:22 am

gotcha, the quest continues...
Aliit ori'shya tal'din - Gar taldin ni jaonyc; gar sa buir, ori'wadaas'la - Ke nu'jurkadir sha Mando'ade!

hrc1966
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Re: Making your own side covers

Postby hrc1966 » Mon Apr 01, 2013 4:44 am


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wdwillis
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Re: Making your own side covers

Postby wdwillis » Mon Apr 01, 2013 5:08 am

unfortunately, the only one of those that might fit is the last one. (mine is a '78, which i clearly did not mention, my bad).
i wasn't searching global ebay sites though, because international shipping can eclipse the cost of the gear pretty quickly...

thanks for the links which brightened up the dim bulb over my head
Aliit ori'shya tal'din - Gar taldin ni jaonyc; gar sa buir, ori'wadaas'la - Ke nu'jurkadir sha Mando'ade!

hrc1966
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Re: Making your own side covers

Postby hrc1966 » Mon Apr 01, 2013 5:30 am

Yeah tell me about shipping.. and customs duty.. I buy in mint originals and my last part cost me US$50.00, Shipping was US$60.00 Duty US$125.00 Handling agent fee US$40.00.. Yeah tell me again...lol And people tell me i am too expensive for the parts i make.. Probably if i was mass producing them.. But hand made parts .. Hence why i don't bother with the project too much anymore..

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wdwillis
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Re: Making your own side covers

Postby wdwillis » Mon Apr 01, 2013 2:15 pm

i can certainly understand that... they get you coming and going with the shipping
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Re: Making your own side covers

Postby gwlegg » Mon Apr 01, 2013 8:35 pm

Have they have seen you somewhere else the lower part of the fairing of my wing? Effectively. They are processed side covers made in fiberglass.
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Look carefully lower fairing
Look carefully lower fairing




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