tjfisher said:Wow great idea's . The reason I'm trying out different designs and shapes are for comfort and function
I'm sure the first won't be the last I enjoy the build and design so 2-10 won't upset me
@ diablouph ya I plan on setting the tail light in the shell I'm waiting on it so I can shape the second seat and it might work in this one too. And it's led so I'll need to wire the bike by hand for neg ground .
Depending on the space in the final design Im hoping to put the battery ( small cell ) and the main fuse block in the tail section
If you want to try some different methods and would like more usable space under the cowl, the forming it in alloy is the way to go. It will also save some weight and the appearance of a polished alloy cowl is hard to beat.
The disadvantage of going this route is the amount of work required. Evan Wilcox charges as much as $1400 for a cowl and seat pan. After doing one, I can see why.
Starting point is to make a buck. Run a dividing bulkhead down the centre. Use heavy paper for the stations and just do one side for starters. You'll be able to see if the shape is what you want from one side only. Play around with the curves on the paper stations until the overal shape is faired.
Once you have the shape you want with the paper stations,, which are positioned on the wooden buck base and centre bulkhead by grid lines, remove the paper stations and lay them over top some plywood to be used for the permanent stations. Trace around the paper stations. Make two of each station, one will go on the right hand side, one on the left.
This gives you perfect side to side symmetry automatically, as long as the wooden stations are fastened in the correct spot (on the grid lines)
Start shaping metal. In this case it is .050 5052 Aluminium. An easier choice would be .063 3000 series, but not quite as light and softer, less dent resistant.
Ive got a ton of wiring on this bike and it all fits under there including two fuse boxes and the largest LIthium Ion battery sold by Ballistic. The electrics are all on an independant al. plate that slides out after disconnecting the weatherproof quick connects. There is a bit of room left for the inevitable additions.