DR650 Rally Fairing DIY

[MartinPetren]

Yesterday, while at work, I stumbled upon this thread and decided to make one of my own. I currently own a DR650 -92 and has been riding a lot of gravel lately. I have a bar mounted GPS and is soon going to purchase a roadbook. Since there is not alot of space in the original "cockpit" I wanted to make room for the new toys by making a fairing, aswell as getting a rallye-look to the bike.

The bike as it is now:



First of all I printed some pictures of a -92 to make some sketches.



Then I took it to the workshop for some measurements and more sketches.



A cardboard model/form was made.



I'll be hitting the workshop later tonight to make some modifications to the form and perhaps start to put fiberglass on it this weekend. I'll keep you updated! And the next time I'll be shooting with this and not my crappy cellphone:



I hope this will catch your interest and that I didn't post in the wrong sub forum.

/ Martin

edit: Fiberglass process takes place tomorrow :) First time creating anything with fiberglass... Any tips?

[mickd]

[Super Sherpa]

This could be good

[vintagespeed]

cardboard mock-up looks good! soak it in resin, sand, paint, done.

[MartinPetren]

I'm back with news! Good and bad news.

We'll start off with the bad:
I forgot to charge the DSLR's batteries so you'll get poor quality pics in this update aswell.

Now to the good news

I wrapped it in aluminum foil and putted some gelcoat on it:



It's only the foil that is lifted from the cardboard in the picture, nothing to worry about.



Here it is with plenty of fiberglass on it! The bubbles in the foil disappeared due to the weight of the polyester and the glassfiber. It's hard to see some of it's original shape because I went quite far over the edge, just to make room for minor mistakes in past measuring.

Now back to the part that I hate.... The waiting! Tomorrow after work it's time for cutting and sanding. I will also start to look over the tower that'll hold the GPS and also the headlight.

[Ben99r1]

Wish I had the skills and patience. but i hate the sound of sandpaper.

[MartinPetren]

Originally Posted by Ben99r1

Wish I had the skills and patience. but i hate the sound of sandpaper.

Well, it might not be the funniest part of the project.. But I found some really rough sandpaper in the store and hopefully it'll go relatively quick.

[vintagespeed]

it's looking pretty good! oh........nice pink bucket.

[MartinPetren]

Pretty much finished sanding the fariring yesterday and drilled two holes for the rear mounts. Made two mounts out of aluminum that I fitted to the front of the tank which holds the fairing. I did also find out I've made it a bit too narrow so that mounting the headlight will be a challenge!



The hole for the headlight is not yet finished. Some adjustments will be made!



I'm going to change the the indicators to smaller ones and I am going to mount them on the fairing.

[torgo]

Any Update?????

[JamesG]

Originally Posted by MartinPetren

Heh, you could have just covered that in duct tape and put it on the bike.

Fiberglass process takes place tomorrow :) First time creating anything with fiberglass... Any tips?

The upper "windscreen" part of the fairing is probably going to crack and get stress lines at that sharp edge to the headlight opening unless you put something like some Al angle behind it as a reinforcement.

[juanla]

very inspiring.
im thiking to do similar fairing to a Qlink 200cc.
any advice from your experience?
what about $$?

[MartinPetren]

Originally Posted by juanla

very inspiring.
im thiking to do similar fairing to a Qlink 200cc.
any advice from your experience?
what about $$?

Be sure to have plenty of time. Takes a few tries to this stuff.. but it's very cheap! 20-25 euro Perhaps.