Started making the front of the cowl, standing it up on an flat surface, then putting filler in the opening between the cowl and the flat surface:
Attachment 27895

Turned out like this:
Attachment 27896

put in the first round of filler:
Attachment 27897


A lot of sanding and filler done, still a lot of sanding and filler left.
Attachment 27898

Attachment 27899

tasty looking speedo & cowl man! love proper home-brew mods, can't wait to see more. one question though, how are you planning on attaching the cowl. fabricating brackets and bolting it in, strapping it round the seat or something completely different? its something that proved enough of an inconvenience at the time to put me off having a cowl

Thanks for the compliments. The method I was planning on using turned out not beeing very durable. It would work perfect if I was planning on mounting it and never take it off again.

I got a few ideas about how I'm going to do it. Since I don't want any screws or mounting points visible, I will need to remove the side panel fairings underneath the seat.

Just so people can see that my garage usually isn't that messy, here's a picture of how it usually looks like ;)
Attachment 27892

Started on the bike again yesterday, as my 2nd son was born on Feb 26th, so I felt I couldn't spend my days in the garage. But now that the snow has more or less dissapperead and more and more of my buddies are posting pics of their bikes on facebook I just had to continue.. :P

I fibreglassed some more on the underside,so it would slide back and forth, and not fall off if I turned it up side down.
Attachment 27788

Ready for some Bondo:
Attachment 27789

Bondo against the rear fairings to make it tight and make the gap similar along the fairings.
Attachment 27790

As of now, it's not possible for the cowl to fall of the bike, it will hardly move if I try when everything is mounted together.

I have also sent my rims off to powder coating. so then I started on a spring service, so that everything is ready to roll when I get them back.

This is how the bike stands as of now:
Attachment 27782

Attachment 27783


I wonder if anyone can tell me about these spark plugs. Are they okay? or should maybe the pilot screw be adjusted? they have about 5000km on them:
Attachment 27784

Attachment 27785

Attachment 27786

Picture of what I'm planning to replace. The spark plugs, oil, coolantand brake fluid is not on this picture though.

Attachment 27778

It was about time to change the fuel-filter. :)
Attachment 27779

Attachment 27780

Awesome work. Props on the hand-made cowl.

Thanks man, Appreciate it :icon_lol:

Haven't updated in a while, as the progress hasn't been exactly blasting away.. :P

Took off the swingarm and washed it thoroughly before i painted it Black:
Before:
Attachment 27741

Washed and prepped for paint:
Attachment 27742

Waiting for the first coat of paint to dry:
Attachment 27743

Cleaned the tank for coolant fluid:
Before:
Attachment 27744

Attachment 27745

After:
Attachment 27746

Attachment 27747

Rear fender prepped for paint:
Attachment 27748

Changed all the bearings and seals in the swingarm.

New vs old Needle bearing in the swingarm:
Attachment 27749

Attachment 27750

I've sent the fairings away to my uncle, so he can do some touch-ups on the paint, so this is how it's hanging at the moment:
Attachment 27751

I have startet on the reassembly of the bike now, with the parts I have at hand.

I have changed the bearings in the Swingarm and the lower mounting point of the rear shock before reassembly. Painted the alternator- and clutch cover, swingarm, rear fender, mounting bracket for the rear brake calipper, the mounting brackets for the passenger footpegs and the passenger handlebar.

I Also mounted the airbox, fuel tank and radiator today.

Attachment 27736

Attachment 27737

Attachment 27738