How to make your own F800GS Carbon Fiber Fork Sliders......

Discussion in 'Parallel Universe' started by ebrabaek, Oct 22, 2012.

  1. ebrabaek

    ebrabaek Long timer

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    So..... along with the other projects......

    http://www.advrider.com/forums/showthread.php?t=678072

    And this set...... Which was made up at a local hose maker for US$ 120.... I was at a go.

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    So I wanted to make a set of fork sliders......MX style, rather than hack the low fender. First I tried to form a piece of lexan..... and while it would have worked fine functionally, It did not look as good as I wanted.
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    So onward with a sheet of 24 gauge steel...... Marked 12x5 inches. When I make things from scratch, I always try to.....uhhhhmmmm... make it from scratch, as not to "reform" others products. That keeps me in the clear, if I ever sell any parts. Copyright laws allows you to make sets for your self, but once you sell further copies, you open yourself up for exposure.
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    Cut to shape.....
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    Bend it on a SS tube, and installed, and drilled the holes, while fit the abs sensor........ Acceptable.....?????
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    These will then serve as templates, for a Carbon Fiber mould...... Should be short work......:evil:freaky:freaky
    #1
  2. toro618

    toro618 Long timer

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    This is a great idea. If you make them with the brake line pinch clamp tabs molded into the upper part of the gaurds...both left and right....I would gladly get in line to purchase a set.

    http://www.motocross-atv.com/Lightspeed-Carbon-Fiber-Brake-Line-Pinch-Clamps-p/667-1587.htm

    I currently run an MX style brake lines and had to screw in the pinch clamp on the right fork. But I would much prefer to have the tab molded in like all the left fork gaurds.
    #2
  3. greenthumb

    greenthumb b00b

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    Awesome. :thumb
    #3
  4. ebrabaek

    ebrabaek Long timer

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    Thanks..... Could be..... But I will have to see how it sits, as the line would add stress to the equation. We shall see.....:D
    #4
  5. ebrabaek

    ebrabaek Long timer

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    Thanks.....:thumb
    #5
  6. ebrabaek

    ebrabaek Long timer

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    All set up, and ready for hardware casting...... Note the outer and inner rings, and Brake line guides...... A quick and dirty dual sided moulding for hardware.....:evil:deal
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    #6
  7. 4TooMany

    4TooMany Been here awhile

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    I have a better idea. Make 'em for the DRZ (S version). You'll get rich selling 'em, and I'll be your first customer.
    #7
  8. ebrabaek

    ebrabaek Long timer

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    :lol3:lol3....... I thought of that many times...... But it would look soooooooo funky half way up there......:rofl:rofl
    #8
  9. 4TooMany

    4TooMany Been here awhile

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    No way, look at all the threads on Thumpertalk about adapting KTM guards to fit a DRZ fork. I'm telling you, there's a market. Nobody likes those stupid black accordion-lookin' things.
    #9
  10. ebrabaek

    ebrabaek Long timer

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    Your right.... Myself including.......:D
    #10
  11. 4TooMany

    4TooMany Been here awhile

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    I'll start saving my pennies. They'll match my heat shield nicely.
    #11
  12. runnin4melife

    runnin4melife Been here awhile

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    Erling, This may be the route that I go as well. I pulled out the KLX forkguards and it will be a lot of work to try and mate anything (heat gun and forming). I might also make a cast using the two portions though as I like the upper plastic styling but need the lower bolt pattern. Either way it is on hold for the moment because it is a nice week and I finished with the fender mount today.
    #12
  13. ebrabaek

    ebrabaek Long timer

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    Yeppers...... Just bear in mind, that those nice lines, can be a bear to conform the fabric over.....:D. It sure was a breeze to mould these. They don't look fancy or anything, but as with most of my pieces..... they serves the purpose.:freaky
    #13
  14. ebrabaek

    ebrabaek Long timer

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    The hardware will now cure over night..... Until tomorrow....
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    #14
  15. runnin4melife

    runnin4melife Been here awhile

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    Are the rings going to hold your brake cables? I am not quite sure how you routed yours but with mine they have a decent range of motion just on the street so make sure you provide as smooth of a guide as possible because they will be traversing it a lot.
    #15
  16. ebrabaek

    ebrabaek Long timer

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    That is the plan......:D. I did not want to route them MX style, but I want something that is going to keep the lines away from the wheel. We shall see after working them today....
    #16
  17. runnin4melife

    runnin4melife Been here awhile

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    So since today was my first legitimate ride after feeling fairly certain nothing would break I popped a few wheelies. Everything held up fine but I did notice something. You might want to take this into account for your brake line guides. During full travel the lower part of the upper fork gets way down there. I got low enough that it torques my cable guides from a 90' angle to a vertical 45. This wasn't too bad but it needs to be fixed to remedy wear and tear.
    #17
  18. ebrabaek

    ebrabaek Long timer

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    I will have a look. I have not even gotten there yet, but the rings will wrap around the fork, and the looooooong ovals, will house the cable....
    #18
  19. ebrabaek

    ebrabaek Long timer

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    Viola....... dos Moulds, ready for their first cast...... Getting exciting now......
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    #19
  20. ebrabaek

    ebrabaek Long timer

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    He he.........
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    :freaky:freaky:clap:clap
    #20