Day 1, let the fun begin!

i would keep the stock air box and put a k&n filter in ,but that's just me less hassle

Sometimes you can tap a SAE socket on it and get it to move.
Keep the air box and K&N filter.
Steve

Couldn't get a 5/8" socket to get on and grab it, going to see what my other options are and then spend the 20 bucks for a new one I guess.

Let it snow, let it snow, let it snow... this ohio weather is definitely slowing down my progress, since I do not have a garage and am doing all my work in the driveway. I love riding my sled but come on spring!

Been a while since I have been on, busy busy at home. Currently waiting on a new oil pan because the drain plug on the current pan is rounded, busted, and not worth putting any more time into trying to remove. Anyone have any advice on custom side covers? One side cover was missing so I am thinking of doing just a flat panel of some sort on each side to cover battery and wiring. I removed the old air box for pod filters but need to cover under the seat. I think my best option is to drill and tap the frame to bolt a new cover on, but have never drilled a frame before, is this bad news?

A quick search on eBay revealed these two lovely side covers:
Hook'em Horns!

May need a little paint I reckon...

Good deal.
Steve

Maybe I should have said I wasn't going for stock haha. Might be easier than making one though. Thanks for the search.

Does anyone have any advice or opinions on drilling and tapping the frame? Rather than welding tabs onto it to bolt the new covers to.

Ohio88ace wrote: Does anyone have any advice or opinions on drilling and tapping the frame? Rather than welding tabs onto it to bolt the new covers to.

From what I have heard and seen the tubing is fairly thin by comparison and could certainly be a weak point that elongates or strips out much easier than a weld on bung by comparison. I am sure that much smarter people than myself would be able to chime in even more, but I would advise against it as there just isn't much meat for the threads to grab to and by drilling it you are introducing a weak point that would be more likely to fail than a weld. As you know these frames take a lot of stress and abuse just with normal riding and the stress and strain the bike puts on it could cause a crack or failure to develop at the point of penetration.

Just my two cents,
Brett

That was exactly my thinking too but just wanted to consult with others. My original plan was to weld on tabs to bolt the covers to, but of course that's more money, even tho it would be a better design.

Ah! Well there's another member here that built his own side covers from steel mesh. He's a UK member if i recall correctly and hand made some kick-azz parts. It may provide some inspiration or ideas...