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Fabricating Side Covers

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    Fabricating Side Covers

    Hello, I have posted recently about my project '81 Gs850g that was recovered after it was stolen. The side covers and back is missing so I decided to build it out as a sorta cafe racer thing, maybe more of a rat bike cuz I'm trying to do it all on the cheap. I think I'm going to fabricate some side covers out of some scrap sheet metal. Anyone try anything like this?
    1981 GS 850G

    sigpic

    #2
    I've always liked these leather pouches Sam makes.
    https://www.thegsresources.com/_foru...ther-side-bags

    Fairly recently, before the forum software change, someone posted pics of some (stainless?) sidecovers they made. Look through the projects/ rebuilds forum and I'm sure you'll find some inspiration.
    Roger

    Current rides
    1983 GS 850G
    2003 FJR 1300A
    Gone but not forgotten 1985 Rebel 250, 1991 XT225, 2004 KLR650, 1981 GS850G, 1982 GS1100GL, 2002 DL1000, 2005 KLR650, 2003 KLX400

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      #3
      Fibreglass is what I would likely try over a foam mold....Need know the "usual foam" around the house is melted by fibreclass resin so needs a plastic bag or waxpaper covering...fg shrinks a little when cured so it can grap protrubances in a mold and mold will be destroyed getting it off....

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        #4
        Sheet aluminium is the most common material.
        Suits cafe and rat builds and is relatively cheap.
        Can be easily shaped and beaten or just left flat.
        Finish can be polished, brushed or painted.
        Made quite a few myself over the years .
        Rarely buy the stuff new though as i have a source of ex highway road signs that come up real nice once the signage has been removed.
        One of my most recent builds in this pic has the tank, tail and mudguards i made from reclaimed alloy signs.
        76710782_2197548197215806_7365907760619192320_o.jpg
        Last edited by zed1015; 05-15-2022, 06:19 PM.
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          #5
          Yea the shop I use has some sheet metal around I was thinking of using. I was also considering the street sign idea that Zed1015 mentioned
          1981 GS 850G

          sigpic

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            #6
            Originally posted by Burque73 View Post
            I've always liked these leather pouches Sam makes.
            https://www.thegsresources.com/_foru...ther-side-bags

            Fairly recently, before the forum software change, someone posted pics of some (stainless?) sidecovers they made. Look through the projects/ rebuilds forum and I'm sure you'll find some inspiration.
            Oh hey bud! Those are some good looking leather pouches at a tempting reasonable price, thanks for the suggestion.
            1981 GS 850G

            sigpic

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              #7
              Ok I did some looking on ebay and theres a company called 4 into 1 that makes reproduction side covers. a set runs $114 also very tempting
              1981 GS 850G

              sigpic

              Comment


                #8
                Originally posted by mrhedges View Post

                Oh hey bud! Those are some good looking leather pouches at a tempting reasonable price, thanks for the suggestion.
                You're welcome. Hope you get that bike sorted and back on the road. Really sux what happened!
                Still riding the Kaw? Concourse right?
                Roger

                Current rides
                1983 GS 850G
                2003 FJR 1300A
                Gone but not forgotten 1985 Rebel 250, 1991 XT225, 2004 KLR650, 1981 GS850G, 1982 GS1100GL, 2002 DL1000, 2005 KLR650, 2003 KLX400

                Comment


                  #9
                  Originally posted by Burque73 View Post

                  You're welcome. Hope you get that bike sorted and back on the road. Really sux what happened!
                  Still riding the Kaw? Concourse right?
                  Yea, I am. It's pretty much my daily driver. What I'd like to do is fix up this GS850 and make that my around town bike and keep the concourse for long distance trips
                  1981 GS 850G

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