TOPIC:

This is only the mold boys. I was hoping to do the real thing this weekend but I have to work tomorrow so itll have to wait. Ive read on here a lot of people struggling to find a nice mudguard and I didnt want to spend money on something that might not work so this seemed the best solution.The great thing about it,is that I get to keep all the mounting holes and the radius so it will fit as well as the original.
Thats the theory anyway. Well see whats what when Ive finished it.

So I filled some of the bigger holes in the mold and tidied it up a bit.

I put it back into the original to trim back the edges

and noticed that it was pulling in a bit from the origina at the sides.

I put a couple of wooden dowels in as spacers to try and compensate for this.
I cut and routed a bit of wood to fit the large holes either side (I think they are to fit over the lip of the fork leg)



Foiled and greased the lot

Built a mount to make life easier

and had at it with the fiber glass

A bit of a trim and a quick going over with the sander and there you have it. A new homemade front mudguard to fit a ZX9R front end.

From the basic shell

I went over it with the filler.There were a lot of high/low spots,pin holes and rough patches.

A rubber scraper worked better than the metal one as it follows the curves better

I sanded and filled it a couple of times and got it as good as I could then layed on the first layer of gelcoat

Im happy with the result so far,though I want to sand it back again and give it another layer or 2 of gelcoat.

And with all this sanding Ive noticed that its gottena bit thin in places so Ill do another layer of fiberglass on the inside to beef it up a bit. Also maybe a bit extra around the mounting holes.( i initially did 3 layers of fiberglass,I should have gone for 4 or 5 I think)
Thats it for now.

nicely done sir!

leon

You have been very industrious Davido. Front fender looks great
Sorry to read about the gear lever though

davido wrote: aces so Ill do another layer of fiberglass on the inside to beef it up a bit. Also maybe a bit extra around the mounting holes.( i initially did 3 layers of fiberglass,I should have gone for 4 or 5 I think)
Thats it for now.

man i know how that goes sometimes... the fiberglass work never seems to end; add, subtract, add, subtract.... Turning out real nice though. much more fitting with the rest of the bike.

Well I got the first layer of gelcoat sanded back today after work. Its tough stuff. Good news for the finished article but a lot of work to get it there. Anyway, I bought some black pigment to mix in with the second layer and was planning to get it layed on today but Im not happy with the area around the mounting bolts and I may have to build up some more fiberglass on the outside as well as the inside.So, Im going to get that done first and make sure everything is hunky dory before I go on with the gelcoats.
I did plonk it on the wheel to get an idea of the finished look and Im well happy with it.

Its a massive improvement over the original ZXR thing and really fits the look of the bike. Now I just have to finish the bugger.

That looks GREAT, & you're becoming a Master Fiberglasser
Pete

I am! Im well into it. Though the proof is in the pudding so we'll wait and see what the final result is.

turned out nice man.

leon

Looks great, I had the same reaction to the stock mudguards around at the moment. They are too fussy, I like a much more simple look like what you have created.

Thanks Gordy, and everyone for your comments. Its nice to log on and find a message. Good to know people are following the build and (hopefully) enjoying it.
Still busy with the fiberglass. Waited all week to get a chance to continue. Took half an hour to lay some extra glass around the fork mount area,then I have to wait for it all to dry. This is a slow process. Back to it tomorrow. I thought it might be more time economical to do some other stuff at the same time. So, I started preparing for the seat pan.
I made a mold of the front of the original seat pan last weekend. The part that raises up to cover the rear mount for the petrol tank. Thats the only part of the old seat Im going to use.

Today I chopped that up and messed around to get it to fit like I want.

Its all taped down now onto the tailpiece unit. A bit of alu tape,some vasaline and I can get the fiberglass onto it. This should give me a good solid well fitting seat pan that I can put some foam on.

Ive raised a section front and center to allow some clearance for the airbox intake. (ill be starting with the airbox to get it on the road.Maybe later Ill switch to pods.Dont know yet)
Hope its not going to bother my huevos!!