DR650 Rally Fairing DIY

Discussion in 'Thumpers' started by MartinPetren, Jul 20, 2011.

  1. MartinPetren

    MartinPetren Swedish Adventurer

    Joined:
    Sep 2, 2009
    Oddometer:
    372
    Location:
    Gothenburg or Uppsala
    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:

    [​IMG]

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

    [​IMG]

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

    [​IMG]

    A cardboard model/form was made.

    [​IMG]

    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:

    [​IMG]

    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?
    #1
  2. mickd

    mickd crash test dummie

    Joined:
    Apr 10, 2007
    Oddometer:
    2,011
    Location:
    brisbane,australia
    :lurk:lurk:lurk
    #2
  3. Super Sherpa

    Super Sherpa The Burning Man

    Joined:
    Feb 25, 2010
    Oddometer:
    308
    Location:
    Red Deer, Alberta. Bitterroot Valley
    This could be good :freaky
    #3
  4. vintagespeed

    vintagespeed fNg

    Joined:
    May 9, 2011
    Oddometer:
    2,541
    Location:
    Rancho Cucamonger, CA
    cardboard mock-up looks good! soak it in resin, sand, paint, done. :D
    #4
  5. MartinPetren

    MartinPetren Swedish Adventurer

    Joined:
    Sep 2, 2009
    Oddometer:
    372
    Location:
    Gothenburg or Uppsala
    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 :clap

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

    [​IMG]

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

    [​IMG]

    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.
    #5
  6. Ben99r1

    Ben99r1 Long timer

    Joined:
    Mar 2, 2006
    Oddometer:
    3,111
    Location:
    Pomona, Calif.
    Wish I had the skills and patience. but i hate the sound of sandpaper.
    #6
  7. MartinPetren

    MartinPetren Swedish Adventurer

    Joined:
    Sep 2, 2009
    Oddometer:
    372
    Location:
    Gothenburg or Uppsala
    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.
    #7
  8. vintagespeed

    vintagespeed fNg

    Joined:
    May 9, 2011
    Oddometer:
    2,541
    Location:
    Rancho Cucamonger, CA
    it's looking pretty good! oh........nice pink bucket. :D
    #8
  9. MartinPetren

    MartinPetren Swedish Adventurer

    Joined:
    Sep 2, 2009
    Oddometer:
    372
    Location:
    Gothenburg or Uppsala
    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!

    [​IMG]

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

    [​IMG]

    I'm going to change the the indicators to smaller ones and I am going to mount them on the fairing.
    #9
  10. torgo

    torgo Adventurer

    Joined:
    Jul 28, 2007
    Oddometer:
    87
    Location:
    Pulling Oil From the Ground In ND
    Any Update?????:norton
    #10
  11. JamesG

    JamesG Rabid Poster

    Joined:
    Dec 31, 2006
    Oddometer:
    10,946
    Location:
    Columbus, GA
    Heh, you could have just covered that in duct tape and put it on the bike.



    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.
    #11
  12. juanla

    juanla n00b

    Joined:
    Jan 17, 2012
    Oddometer:
    1
    very inspiring.
    im thiking to do similar fairing to a Qlink 200cc.
    any advice from your experience?
    what about $$?
    #12
  13. MartinPetren

    MartinPetren Swedish Adventurer

    Joined:
    Sep 2, 2009
    Oddometer:
    372
    Location:
    Gothenburg or Uppsala
    Be sure to have plenty of time. Takes a few tries to this stuff.. but it's very cheap! 20-25 euro Perhaps.
    #13