GSX1100EFE Rebuild

[ensure]

Step 1 was to cut up some lengths of flat plastic to use as the mounts. I have used the lid off small electrical trunking.

I marked up where I wanted it to go

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I then glued it to the fairing and left it to set.

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I then fibreglassed it on properly on the underside so that infill panel will sit flat on mounting bracket. You can see a few threads of glass sticking out from underneath

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Then I had to create a mounting point for the lower connection. I made a cardbord funnell the right shape and taped it onto fairing it corerct spot (hopefully)

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I then filled it up with resin and stuffed glass fibre in there

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Once it was all set I drilled some holes to line up with infill panel.
I did a dry run install and it seemed fine

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Once I installed the fairing on the bike the panel would not quite line up properly.
Digging a bit deeper I found that the fairing bracket was slightly twisted. The one off bike (black) vs my spare one (blue) shows a moderate offset.

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I had half dropped the bike off the sidestand onto the garage wall a while back but hadn't really thought the twist was bad enough to fiddle with as I havent had the full fairing on.
Once I gave it a twist and straightened it up it all lined up Ok




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So here she is all finished

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And the big news is I sold it. I was advertising a few bits for sale and I got talking to a guy. I showed him a photo and he offered to buy it. Saves me the hassle of having to get it reregistered for the road. On the downside I now only have 5 bikes in the garage.

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[dorkburger]

Again, I'm impressed.
Regarding the fill panel, I've always thougt it would be cool to leave it completely out and paint the inside to mimic the outside. I have three of those panels, all horribly weathered. I took one and gave it a major trim... Its cool to be able to look fown and see the top of the engine again. I also like the heavily cut down fairing you showed a ways back.

[slayer61]

Very well done Sir. Your fab skills are commendable. Cheers to you.

[ensure]

From Dorkburger I also like the heavily cut down fairing you showed a ways back

I found a couple of other older photos with the smaller fairing on so you can get a better look

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Its now sittingon a shelf in the garage as I didn' t sell it with the bike.

[wyly]

I have one of those small fairings somewhere in my garage too.

Great fab skills, you work three times my speed.