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Old 01-27-2013, 08:37 PM   #1
richarddacat OP
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Joined: Nov 2006
Location: land of a new Rising Sun
Oddometer: 3,202
Making a Smuggler?

I'm starting my first attempt at fiber-glassing by making a storage box out of the rear seat pan from a FJR. A homemade Corbin Smuggler so to speak.

My idea is not to make a mold but use layering on top of a cardboard fabricated structure. Beginning with a stock seat pan I'm building the box on top of the stock plastic pan.

This outside shell is built of cardboard will be covered with aluminum tape, a release product like paste wax will be smeared on it and then start applying the FG.
The completed shell will be smoothed out with Bondo and probably rattled canned. The lid of course will have a hinge and latch, details of this are or any of it are not drawn out, just a idea I've had in my head.

The shell is now built out of cardboard but I need to fab the attaching brackets so to speak to the base pan.
My idea on this is to build a second piece that's will be on top of the seat pan, doing this I can bolt the new FB to the pan then the new base can be attached to outer shell from the inside. Maybe at the same time the outer piece is being glassed, not sure yet how best to go about it.

I'm tossing ideas about supporting tabs, sheet metal bracketing (?) in four locations where holes can be drilled and bolts run through the seat pan and in the new seat pan base.

The lid will be a third piece.

I'd like to get any input to see if my idea will work or if anyones done a similar project. I've seen a aux. fuel tank built from the rear FJR seat pan, it looked little crude but effective.

I've done a little searching on here about some very creative projects from some very skilled bikers and saved a few links that are helpful. I'm not very skilled but particular and tend to get in a hurry so I'm vowing right now that this is something I don't need to rush.

Tips and suggestions are welcome.
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