First Generation Ascots > The Thumper Years: Modified To Full Customs

let the fun begin

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ex119x:

--- Quote from: WTF304 on April 11, 2015, 11:56:07 pm ---That headlight cowl/front number plate .... what that come off of ? ..... and that steering damper ... what brand and does that bracket to the frame weld on or were you able to simply but it up ?

--- End quote ---
I don't want to threadjack his build thread, but the front numberplate was some NOS pieces that were being liquidated at the Mid-Ohio VMD races a few years ago. It was oem Cannondale. I have seen some like it, it might be UFO. The steering damper is OEM Suzuki GSXR. I grab them off of e-bay whenever I need one for keeping around. I won't spend much on them so I usually find one with a $0 bid and no shipping and bid about max $10 and see if I win. I usually bid on a couple and if I get one great, if not I just look for another. I just like to have at least one in my tool box. I think I have it mounted with a fork tube bracket and with a piece of L shaped steel that goes up under the tank and bolts to that mystery tube under the steering neck. The bracket is 1/4" steel with 1 inch wide and one leg that is about 3-4" long that goes under the tank and the leg that the damper bolts to is about 1.5". I'll look to see if I have a pic somewhere since my bikes are 4000 miles away from where I live most of the year. If so I'll post them up in my race bike thread.

thumb:
Got a few more things done over the past week
1. Side panels cut and reshaped - didn't take any pics of this
2. infill piece for tail piece/seat made
3. new exhaust can mounted

1. side panels first cut like the grey/green ft from the various pics recently posted. Looked o.k but not quit to my liking. Out with the masking tape and "French curve" stencils and got the shape I liked - Cut and shaped with trusty power file. The section that sits under the seat was cut back to about 1/4'' and panel fitted to bike, used some fine aluminium mesh cut to shape of panel and held it in place with a couple of drop of Super glue and pulled over top frame rail to create a nice curve and taped in place then fibre glassed over mesh using the tissue matting taking it right over frame rails and let cure. Once cured I marked a line across the fibre glass and cut back to the line. This sits nice under seat unit and holds panel in place without any more fixings .still need a bit of work to finishing off . Will do a step by step on this if anyone's interested in another post
2. Made this up to fill the open end of the seat unit and allow rear light and reg plate to be mounted. Placed seat unit on its end and drew around it to get the shape required and cut out. Found a piece of board larger that shape and covered with kitchen foil and then laid 2 layers of fibre glass/ resin and let cure. Once cured removed from board and placed paper patten on it and marked around it with pen then cut excess fibre glass away and filed and shaped until it fitted in seat/ tail piece. this will be fibre glassed in place from the inside and any gaps filled with "filler/ bondo" and rear light and reg plate fitted to it
3. Exhaust came the other day, beautiful welds and curves, and only 40cm long. This was a easy fit length of exhaust pipe cut longer than required and placed over original pipe and a tack weld to hold in place. New exhaust can  placed on top of pipe and marked when everything looked good., cut pipe and refitted end can and made a bracket to support it. job done
 

thumb:
A couple more pics, also found some clocks in shed

thumb:
Got the battery box made
Redid the loom - checked of breaks and re taped
Redid the electrics tray and loaded it up
De lugged the frame

thumb:
Got a bit more body work done this weekend, got the rear light mounted in the seat unit and extended the sides of the seat unit so the top frame rails can't be seen. This also allows the side panels to "flow" into the seat unit. Got the rear indicators mounted, drilled out original grab rail mounts into top frame rail and will run wiring that way. Used a couple of rubber bungs to blank off frame rails that were cut also fitted a couple of super bright L.E.Ds into bungs and these will be wired into brake light. Fired her up and she sounds sweet with that new tail pipe, but leaking fuel from fuel pipe at carb end ( need I.D of fuel pipe) to replace

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