Final Cutting

Based on some suggestions from an online forum, and utilizing some black electrical tape to guess the final configuration, I trimmed the upper fairing back again, after marking it out with a sharpie.  The line follow the angle of the seat pan for a sense of symmetry.

Pretty happy with the end result.  The upper sorta looks like that of a TRX850, but it still has a nice retro vibe, and utilizes the mounting brackets I had fabbed up earlier.

A couple more views.  I went at it with some sandpaper to smooth off the edges, and I was able to trim it up quickly with an angle grinder.  With a fine sharp blade, it made quick work of the fibreglass.

The left side.  The aluminum brackets for the light will be radius-ed to clean them up a bit.

Next step is the turn signals.  After careful measuring, checking, and re-checking, I drilled the mounting holes.  This location makes far more sense than under the tank.  That location had the lights themselves somewhat obscured and looking a bit "off".  This puts them in quite a visible location and all is legal for the DOT man.

I made a cardboard battery box, and have sent it off the Iron Craft to be welded out of aluminum.  I cut and bent the pieces based on the template so it should be good to go shortly for a test-fit and mounting.

More work on the blandit...

Continuing to work on the fairing fitment.  Also installed the endurance headlight -- 4.25", with a high and low beam to be DOT compliant.  Also came up with a cheeky idea to install the turn signals, using the old bandit fairing bracket.  That way I don't have to drill any more holes in the headlight fairing.

Have also wired in the turn signal and licence plate light.  Got the plate bracket off of ebay for pretty cheap, saves me trying to fab something.  As I might have mentioned before, the tail light bezel with be refinished in flat or satin black, not chrome.

Fitted an R1/R6 master, from a collection of spare parts I had from my old racebike.  Apparently these work well with the Nissin 4-pot calipers.

Need to fab a bracket for the clutch resevior when it comes in.

Clutch lever is a zx14 model, although the elbow got damaged in shipping so I need to buy a new one of those.  The alloy headlight bracket will be cleaned up and ends radiused when I get a chance.

Front fender we damaged from the wreck, so I thought I'd trim it as I wouldn't lose anything -- however I feel it now sits too tall above the tire.  Can't really space it downward due to the design of the fork brace (I tried).  Thoughts?

600 work

Another obscenely cold stretch of weather results in more work on the xt600 engine.

Jug installed, with cylinder bored out for a 98mm piston.  Work done by Sun N Snow out of Portage.  Balancer shaft, oil pump, clutch basket kickstarter mechanism all in place.  Need to wait on some more parts...

I won't tell anyone if you don't!  All ring end gaps within factory specs.