Fabricating Side Covers

[mrhedges]

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?

[Burque73]

I've always liked these leather pouches Sam makes.

https://www.thegsresources.com/_forum/forum/consumer-information/gs-parts-and-services/84226-i-make-leather-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.

[Gorminrider]

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....

[zed1015]

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

[mrhedges]

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

[mrhedges]

I've always liked these leather pouches Sam makes.

https://www.thegsresources.com/_forum/forum/consumer-information/gs-parts-and-services/84226-i-make-leather-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.

[mrhedges]

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

[Burque73]

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?

[mrhedges]

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