KLR Dakar Fairing and windshield project

Discussion in 'Thumpers' started by Gerald Kubiak, May 12, 2010.

  1. Gerald Kubiak

    Gerald Kubiak Adventurer

    Joined:
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    Well, I've seen it done before but haven't seen anything that really caught my eye. So I ventured off into design and fabrication territory and decided to fab up a Dakar fairing and a windshield for my '08 KLR. My goal was to make a set of fairings that use the existing bolt pattern and butt up to the cowling, yet have a more aggresive "Dakar" look. (Is it me, or does the [new] KLR come real close to having that classic Dakar bike look?!? I wanted to see if I could peel off a few layers and find it...)

    Heres what I had in mind...
    (found an old real estate sign - the corrugated plastic ones - and hacked it up to get my shape)
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    With my trusty real estate sign, I got close to the shape I was after. After that I wasn't quite sure where I was going to go yet. Either do a fiberglass layup over the bike, or ??? The problem was the curves. How do I retain the curvature in the corrugated plastic? Its springy, and would spring right back to flat once its off the bike.

    Anyway, I took some duct tape and filled in the gaps and holes and try to get a smooth transition into the radiator (and the blank side). Also I wanted to stiffen the plastic up a bit (in hopes that it might retain some of the curvature once its removed from the bike).

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    more to come...
    #1
  2. Gerald Kubiak

    Gerald Kubiak Adventurer

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    So, I hooked up with a friend that does fiberglass work and left my fairings with him (the originals and my new Dakar ones). He's going to make me a fiberglass replica of the original fairings with some extra padding so I can come it later and duplicate the shape I want. This way, the bolt pattern is retained, the stock fairing "curvture" around the tank and I'll know that it'll butt up nicely to the cowling.

    Should have something next week...

    In the meantime, it was perfect time to fab up a new windshield (or a mold anyway). What I wanted to do here, is bring up the windshield some (not as much as the "Tall KLR Windshield" you can buy)... And add a wind deflecting lip to the top. I'm after a mold to give to my local plastic vendor to layup some acrylic or makrolon and make a windshield.

    I started with a 5 gal bucket. Cut the side out and started shaping.
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    Added bondo to the surface and started sanding. Found an old ski wax iron and used that to locally heat the mounting flap. Worked very well I might add...

    Lots of sanding later and I started seeing what resembles a windshield (out of my bucket)...
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    Had a few iterations with the bondo to really build up the wind lip. And more sanding, and I had a mold!

    Now to see what a final product might look with my new mold, I layed up 2 sheets of fiberglass over it. Before I head over to my plastic shop, I wanted to see what I was working with...

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    All in all, I didn't think it turned out that bad.

    Once it dryed, i took the original windshield and used it as a template to get my mounting points, cut off the excess and I had a mock windshield.

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    Some trimming, some more sanding and I had a pretty close to perfect fit. I'll have to go back and touch up the mold before handing it over, but not too bad for the first go around... Especially for a computer guy!

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    I have a few more ideas that are a bit more aggressive with the angle. Once I have a few samples made, I can start experimenting - and see what happens...
    #2
  3. beeper

    beeper Badger tickler

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    Looking good!
    #3
  4. Greyhair

    Greyhair Greyhaired Traveler

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    I like the start but unless your 5' 2" I think you will need some more heigth on the shield.
    #4
  5. Cumbacheech

    Cumbacheech XRated

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    :lurk
    #5
  6. Mike JRA

    Mike JRA Been here awhile

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    Very nice work, looking forward to seeing the fairing.
    #6
  7. MSO BOUND

    MSO BOUND Fat Bastard!

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    I like the way this looks. Please keep us posted.
    #7
  8. Gerald Kubiak

    Gerald Kubiak Adventurer

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    Back at it tonight. I cut my mock windhshield and pushed up the face to more of a vertical position.

    Some more bondo and trim work - but I think its getting closer...

    Thoughts? Opinions?

    I think this will come much closer to covering the taller riders too...

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    #8
  9. Gerald Kubiak

    Gerald Kubiak Adventurer

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    More angles...

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    #9
  10. The Mass

    The Mass Timbuktu or Bust... Both!

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    :thumb
    #10
  11. DirtyDog

    DirtyDog Omnia mea mecum porto

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    Tulsa... it's OK
    keep up the good work.
    #11
  12. hoyks

    hoyks Tightass KLR rider

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    :lurk

    I'm all inspired now you have shown the way. I tried to bend the factory large screen to make it a little more upright, but it didn't work, just bubbled where the heat gun over cooked it:cry.
    #12
  13. Ironhead

    Ironhead But Itsa Dry Heat

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    That thing is looking super bitchin:thumb

    I'm lookin forward to seeing the end results:D
    #13
  14. john_aero

    john_aero Long timer

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    looks very good, say 1 inch max more height and be ideal, only down side is if too high then dont see too much in front hahaha.

    looks spot on and will realy suit the bike
    #14
  15. Gerald Kubiak

    Gerald Kubiak Adventurer

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    Windshield is done! (the proto anyway - off to the mold shop now)

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    #15
  16. Gerald Kubiak

    Gerald Kubiak Adventurer

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    Now... what to do with the corner nips?!?
    Chop or bring the windshield down to it?
    I like the line the cowling makes - i think it should follow that line up.

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    #16
  17. Gerald Kubiak

    Gerald Kubiak Adventurer

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    I wish it was that easy! To do what you're trying to do, takes an oven and a mold (or a quick hand during drying)....
    #17
  18. john_aero

    john_aero Long timer

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    i would bring the screen down to mee tthe corners as not adding much to the screen and as it curved section and would add strenght
    #18
  19. NewHampWoodsRider

    NewHampWoodsRider Tag Captor

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    Very cool!!
    #19
  20. hellbent181

    hellbent181 2RM

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    Gerald, nice work in the windshield - I am sure that there was more than a few hours of sanding to get such a nice finish. I can't wait to see what you are going to do with the fairing.
    #20