Well then… I need to move forward step by step, even if just a little.
Today I’ll be fixing the cowl and creating clearance at the contact points.
I’m going to skip ahead…
I’m too lazy to remove it and take photos, so I’ll leave it as is.
Using the GSX250S/400S as reference… it’s a split structure. Easy to recover if needed.
I could have welded it to the frame, but given the shape would require difficult fitting and there’s the original factory weld bead in that area that I’d need to avoid… I was concerned about whether it would be okay.
The left and right sides came out like this. The reinforcement might be a bit overkill.
Better strong than weak, I figure.
I’ve welded nuts to the back side, so maintenance access is excellent.
The stock stem makes it contact a lot…
If I position it so it doesn’t contact, the fairing angle gets weird.
I applied patches in two pieces, but since thin material is thin, I bent a round rod and docked it in. This reinforcement worked amazingly well.
Just the right side for now…
I’ve been attaching and removing it so many times—seriously, how many times am I going to do this?
I’m never taking on custom or modification work again… absolutely not.
To be continued.
