My RZ350 Project in Austin, TX

[wolfeman28]

ImgBB is a great free hosting option

[mixalive]

I finished molding the lower fuse box cover. I will clean up the outside of the part and paint it after I create a wire exit before installation.

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Continuing work on the body work. The lower cowling halves seem to have the mounting tabs missing. So here is how I am dealing with it.

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Keeping the halves together:

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I had removed the plastic radiator grill and mounts earlier in the build. I am building a grill to protect the radiator from rocks using some expanded metal left over from some sub woofer projects. Not pretty but should be effective and will be tucked under the bodywork. I made the brackets out of 1.5" rectangular tube. The bottom brackets were no problem but had a hard time figuring out where to anchor the top brackets until i realized the fairing brackets were right there. It should it around the aftermarket aluminum radiators as well.

Basic cutout


Brackets installed


Installed

[mixalive]

I have also been slowly working out the defects on my bodywork. Here I grafted a new stay on one of my side covers using ABS pipe cement.

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The FZR400 right side lower has this hole for engine clearance that of course did not match up with the RZ engine. I filled in the hole with ABS sheet and re-cut a relief for the RZ engine. I need to repair that vent as well.

Before


The modification. The bottom edge of the engines clutch cover protrudes beyond the lower. This relief looks big in the image but will only reveal the oil pump protrusion and part of the Yamaha clutch cover emblem.

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Kickstand relief.

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Now I have to fill up this big hole.

[TwoStrokeNut]

Been following along for a while now and enjoying the updates... keep up the great work. I'm guessing the fairing is slightly concave where that big hole is, so I'll be interested to see how you tackle filling it. Its going to be a great looker when finished.

[RuZty]

I like what you are doing with this. I've got a similar project in the works to fit an FZ600 fairing using the upper and mids, but I'm splicing the FZ600 lower to the stock RZ full fairing because it fits the bike better.

[mixalive]

Been following along for a while now and enjoying the updates... keep up the great work. I'm guessing the fairing is slightly concave where that big hole is, so I'll be interested to see how you tackle filling it. Its going to be a great looker when finished.

I was wondering if I was the only one on here. Thanks for the encouragement.

I have been brainstorming today on how to deal with this hole. I am thinking I will temporary back the hole with heavy aluminum foil, back fill the hole with modelling clay, let dry, work the curve with sand paper. Then do a negative mold of the outside with modelling clay, let dry till hard and use that for the mold for vacuum forming a positive ABS plug with 1/8" ABS sheet.

I don't know.. Still brainstorming..

[JonW]

you could also heat up some flat sheet until you get the parts you want to have the right curve, Ive had good success with heat on plastic but you need to be subtle with it.

[mixalive]

I like what you are doing with this. I've got a similar project in the works to fit an FZ600 fairing using the upper and mids, but I'm splicing the FZ600 lower to the stock RZ full fairing because it fits the bike better.

Do you have a thread for your project? I would like to check it out.

[RuZty]

Not yet, I took lots of pictures so I intend to start one at some point, maybe over the winter.
Here is a pic of the spliced fairing before I did the R6 forks and RGV swingarm swap;



I don't like the hole Yamaha cut in the fairing for the oil pump cover that they couldn't be bothered to change from the earlier bike so I cut the circular part off the cover and bonded it back on cut to an angle. It will now fit below the plane of the fairing so I can cover the hole. I will have to trim the back edge of the fairing mids by about 2 inches to clear my knees.