My upper fairing stay is broken - Revision history

Bokonon: /* Making a stronger bracket */

2010-08-29T07:49:54Z

Making a stronger bracket

← Older revision		Revision as of 03:49, 29 August 2010
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	*A: ~70mm		*A: ~70mm
	*B: ~30mm (lower corner needs to be rounded as described below)		*B: ~30mm (lower corner needs to be rounded as described below)
	*C: ~~~15.7mm~~ (bolt hole diameter: 6.4mm)		*C: ~20mm (bolt hole diameter: 6.4mm)
	*The hole in the center where post would go through is ~16mm		*The hole in the center where post would go through is ~16mm

Bokonon: /* Making a stronger bracket */

2010-08-29T01:49:04Z

Making a stronger bracket

← Older revision		Revision as of 21:49, 28 August 2010
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	*The hole in the center where post would go through is ~16mm		*The hole in the center where post would go through is ~16mm

	[[image:813132.png\|150px]]		:[[image:813132.png\|150px]]

	It can also ~~be done~~ without a welder -- use a long bolt through the strut to hold the new bracket into place. You may need to trim the bottom of the strut if you use the bolt; there isn't a lot of clearance where the bolt head goes.		You can also mount the new part without a welder -- use a long bolt through the strut to hold the new bracket into place. You may need to trim the bottom of the strut if you use the bolt; there isn't a lot of clearance where the bolt head goes.

	To remove the broken bracket pieces, grind down the weld on the end of the fairing stay, then beat the bracket ring (all that should remain after the angles snap off) right off the end of the fairing stay post. Here's a couple shots of the fairing stay with the old bracket remains removed:		To remove the broken bracket pieces, grind down the weld on the end of the fairing stay, then beat the bracket ring (all that should remain after the angles snap off) right off the end of the fairing stay post. Here's a couple shots of the fairing stay with the old bracket remains removed:

Bokonon: /* Making a stronger bracket */

2010-08-29T01:42:53Z

Making a stronger bracket

← Older revision		Revision as of 21:42, 28 August 2010
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	[[Image:fairing stay2.jpg\|150px]]		[[Image:fairing stay2.jpg\|150px]]

			Here are the measurements that one of our guys came up with. YMMV. He used 3/4" wide x 1/8" thick flat steel, with these ''approximate'' dimensions:

			*A: ~70mm
			*B: ~30mm (lower corner needs to be rounded as described below)
			*C: ~15.7mm (bolt hole diameter: 6.4mm)
			*The hole in the center where post would go through is ~16mm

			[[image:813132.png\|150px]]

	It can also be done without a welder -- use a long bolt through the strut to hold the new bracket into place. You may need to trim the bottom of the strut if you use the bolt; there isn't a lot of clearance where the bolt head goes.		It can also be done without a welder -- use a long bolt through the strut to hold the new bracket into place. You may need to trim the bottom of the strut if you use the bolt; there isn't a lot of clearance where the bolt head goes.

Bokonon: /* Making a stronger bracket */

2010-07-03T06:57:16Z

Making a stronger bracket

← Older revision		Revision as of 02:57, 3 July 2010
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	With the upper fairing stay bracket removed and the tube cleaned up, position the new bracket on the tube. Weld it on. The end of the tube should not protrude through the hole in the bracket, since there is minimal clearance to the frame in that area.		With the upper fairing stay bracket removed and the tube cleaned up, position the new bracket on the tube. Weld it on. The end of the tube should not protrude through the hole in the bracket, since there is minimal clearance to the frame in that area.

	~~It is important to note that the~~ thicker bracket material will require new hardware to mount the stay to the frame. Something in the neighborhood of M6x14mm bolts is what you~~'ll probably~~ need.		The thicker bracket material will require new hardware to mount the stay to the frame. Something in the neighborhood of M6x14mm bolts is what you should need.

	~~Also very~~ important to note is that the lower corners of the bracket need to be removed to clear the lower triple tree as the handlebars are turned. Use a Dremel tool cutoff wheel and clean up the edges with a grinding stone bit.		It's important to note that the lower corners of the bracket need to be removed to clear the steering stop on the lower triple tree as the handlebars are turned. Use a Dremel tool cutoff wheel and clean up the edges with a grinding stone bit.

	[[image:IMG_9420.jpg\|100px]]		[[image:IMG_9420.jpg\|100px]]

Bokonon: /* Making a stronger bracket */

2010-07-03T06:48:34Z

Making a stronger bracket

← Older revision		Revision as of 02:48, 3 July 2010
Line 39:		Line 39:
	Also very important to note is that the lower corners of the bracket need to be removed to clear the lower triple tree as the handlebars are turned. Use a Dremel tool cutoff wheel and clean up the edges with a grinding stone bit.		Also very important to note is that the lower corners of the bracket need to be removed to clear the lower triple tree as the handlebars are turned. Use a Dremel tool cutoff wheel and clean up the edges with a grinding stone bit.

	[[image:IMG_9420.jpg\|~~150px~~]]		[[image:IMG_9420.jpg\|100px]]

	Pictures showing the new bracket holding the fairing stay in position:		Pictures showing the new bracket holding the fairing stay in position:

	~~[[image:fairing stay 4.jpg\|150px]]~~		[[image:IMG_9417.jpg\|100px]]
	[[image:IMG_9417.jpg\|~~150px~~]]		[[image:IMG_9418.jpg\|110px]]
	[[image:IMG_9418.jpg\|~~150px~~]]		[[image:IMG_9419.jpg\|100px]]
	[[image:IMG_9419.jpg\|~~150px~~]]

Bokonon: /* Making a stronger bracket */

2010-07-03T06:43:52Z

Making a stronger bracket

← Older revision		Revision as of 02:43, 3 July 2010
Line 38:		Line 38:

	Also very important to note is that the lower corners of the bracket need to be removed to clear the lower triple tree as the handlebars are turned. Use a Dremel tool cutoff wheel and clean up the edges with a grinding stone bit.		Also very important to note is that the lower corners of the bracket need to be removed to clear the lower triple tree as the handlebars are turned. Use a Dremel tool cutoff wheel and clean up the edges with a grinding stone bit.

			[[image:IMG_9420.jpg\|150px]]

	Pictures showing the new bracket holding the fairing stay in position:		Pictures showing the new bracket holding the fairing stay in position:
Line 45:		Line 47:
	[[image:IMG_9418.jpg\|150px]]		[[image:IMG_9418.jpg\|150px]]
	[[image:IMG_9419.jpg\|150px]]		[[image:IMG_9419.jpg\|150px]]

	~~This shows the possible area of interference between the lower triple tree hard stop nub and the new bracket:~~

	~~[[image:IMG_9420.jpg\|150px]]~~

Bokonon: /* Making a stronger bracket */

2010-07-03T06:41:45Z

Making a stronger bracket

← Older revision		Revision as of 02:41, 3 July 2010
Line 39:		Line 39:
	Also very important to note is that the lower corners of the bracket need to be removed to clear the lower triple tree as the handlebars are turned. Use a Dremel tool cutoff wheel and clean up the edges with a grinding stone bit.		Also very important to note is that the lower corners of the bracket need to be removed to clear the lower triple tree as the handlebars are turned. Use a Dremel tool cutoff wheel and clean up the edges with a grinding stone bit.

	~~Here's a picture~~ showing the new bracket holding the fairing stay in position:		Pictures showing the new bracket holding the fairing stay in position:

	[[image:fairing stay 4.jpg\|150px]]		[[image:fairing stay 4.jpg\|150px]]
			[[image:IMG_9417.jpg\|150px]]
			[[image:IMG_9418.jpg\|150px]]
			[[image:IMG_9419.jpg\|150px]]

	This shows the possible area of interference between the lower triple tree hard stop nub and the new bracket:		This shows the possible area of interference between the lower triple tree hard stop nub and the new bracket:

	[[image:~~fairing stay 5-2~~.jpg\|150px]]		[[image:IMG_9420.jpg\|150px]]

Bokonon: /* Repairing the one you have */

2010-05-31T01:18:53Z

Repairing the one you have

← Older revision		Revision as of 21:18, 30 May 2010
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	====Repairing the one you have====		====Repairing the one you have====

	If you still have all the pieces you can just get someone to weld them back on. This one has gone 15,000 miles since the repair. It's stronger than the original and still works fine.		If you still have all the pieces, you can just get someone to weld them back on. Weld the broken pieces together, then run a weld along the bracket to strengthen it. This one has gone 15,000 miles since the repair. It's stronger than the original and still works fine.

	[[Image:p4205367.jpg\|150px]]		[[Image:p4205367.jpg\|150px]]

Bokonon at 20:46, 30 May 2010

2010-05-30T20:46:34Z

@@ Line 5: / Line 5: @@
 [[Image:fairing stay1.jpg|150px]]
 ====Making a stronger bracket====
@@ Line 36: / Line 46: @@
 [[image:fairing stay 5-2.jpg|150px]]

Bokonon at 20:45, 30 May 2010

2010-05-30T20:45:55Z

@@ Line 5: / Line 5: @@
 [[Image:fairing stay1.jpg|150px]]
 The bottom part of the bracket (stay) was designed for obsolescence. Bring the pieces to anyone that has a welder and have a new piece welded to the bottom of the strut. Either 3/4" or 1" flat steel strap can be bent, drilled, and then welded into place. The strap will have a lot more strength than the lightweight piece that Kawasaki uses. It will weigh a few grams more, but it won't break again.
@@ Line 34: / Line 36: @@
 [[image:fairing stay 5-2.jpg|150px]]

← Older revision		Revision as of 02:48, 3 July 2010
Line 39:		Line 39:
	Also very important to note is that the lower corners of the bracket need to be removed to clear the lower triple tree as the handlebars are turned. Use a Dremel tool cutoff wheel and clean up the edges with a grinding stone bit.		Also very important to note is that the lower corners of the bracket need to be removed to clear the lower triple tree as the handlebars are turned. Use a Dremel tool cutoff wheel and clean up the edges with a grinding stone bit.

	[[image:IMG_9420.jpg\|~~150px~~]]		[[image:IMG_9420.jpg\|100px]]

	Pictures showing the new bracket holding the fairing stay in position:		Pictures showing the new bracket holding the fairing stay in position:

	~~[[image:fairing stay 4.jpg\|150px]]~~		[[image:IMG_9417.jpg\|100px]]
	[[image:IMG_9417.jpg\|~~150px~~]]		[[image:IMG_9418.jpg\|110px]]
	[[image:IMG_9418.jpg\|~~150px~~]]		[[image:IMG_9419.jpg\|100px]]
	[[image:IMG_9419.jpg\|~~150px~~]]