How to: Poor man's fender eliminator

[SundayDriver]

How to: fender eliminator

As much as I’d like to take credit for this idea, it was modeled after sixtsix’s (from Sportbikes.net) ZZR-600. Stop in and register there and visit the ZZR-600 forums to tell him thanks. ;)

Materials needed:

Thin sheet metal, about 12”x18”
Rubber undercoating
Black silicone
Random nuts/washers/bolts
Universal turn signals (if you don’t have smaller ones already)
Potato salad
Band-Aids
Handsaw
Drill/drill press
Tin snips
Jigsaw
Angle grinder
Razor




So you’ve decided you want to get rid of that ugly fender on your nice, new sport bike, but you don’t want to spend $200 on a kit. You could spend 30-40 dollars and have that’ll do the trick just fine.





Well, first things first, you’ll need to cut off that old fender using the handsaw, then finish it up with the razor.

[SundayDriver]

Now, after its cut, you’ll have to take measurements to cut the plate down to. Use the jigsaw and carefully cut the piece you need out of your piece of sheet metal. Then use the tin snips to adds some finishing touches, and finally use the angle grinder to smooth it out.



Since I messed mine up a little, I also had to bend the sheet metal up so it’d fit under the taillight, and still be flush with the bottom of the trunk.



Then breaktime:



Now put the plate up to the bottom of the tail for the final measurements so you can cut it down to fit perfectly. Once again, use the tin snip and angle grinder to get a nice looking piece of metal.

[SundayDriver]

You may also have to make another plate to make the bottom of the truck meet the plate that you’ve got on the bottom. I used a 2x6” piece of steel, and undercoated it the same way. It worked perfect.

After that I cut 2 2x2” squares out of the sheet metal, and then drilled a hole in the middle. Be careful, clamps can slip and fingers are easily slit open. Luckily, I didn’t need stitches, but my fingers will be wrapped up for awhile.



Cut one 1x1” corner out of the 2x2” square, and then drill holes the steel into the shape to hold the license plate and turn signal.



Then bend the side that’ll hold the turn signal to a 90* angle, and the side that’ll be attached to the bike to a 45* angle.



Now it’s time to apply that undercoating, and to wait until it’s dry.



Once it’s dry you can begin piecing the tail end back together. Attach the large bottom plate first, then add the piece that’ll fit in the trunk.

[SundayDriver]

Use some black silicone inside to fill the gaps and seal the trunk.



Now, attached the turn signal to the turn signal/license plate mounts. Then attach them to the bottom plate, and attach your license plate.



Almost there; put the rest of your tail end back on, and now you can ride around town confident that your rear end is no longer chunky and ugly.

[94rf900r]

jsut to add somehting with those two bulb tail lights you can integrate the turnsignals into them with a trailer light converter. you can get it at pretty much any auto parts store. they are around $10-$15 the converter takes care of the problem you would have buy jsut splicing the turn signals directly into the tail lights, you could put your turn signal on but when the brake is applied it would cause the blinking to stop.