Making custom side panels - any ideas?

jmarkha1 · Apr 29, 2012

I am putting together a stripped down XS - probably closest to a tracker.
For the side panels I was thinking of making some flat alloy panels fitted using dzus clips with cutouts for the pod air filters.
Anyone done anything similar? I have search google and this site but not many options other than no panels or original.\thanks for any ideas...

yamaman · Apr 29, 2012

make your trials with cardboard or thin mdf, with the mdf, or good cardboard, you can spray it with water to shape it, and easily sand the edges. hell you can even do the final product in mdf with a good sealer and paint. please post a few pics as you go, cheers

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xsPete · Apr 29, 2012

jmarkha1 said:
I am putting together a stripped down XS - probably closest to a tracker.
For the side panels I was thinking of making some flat alloy panels fitted using dzus clips with cutouts for the pod air filters.
Anyone done anything similar? I have search google and this site but not many options other than no panels or original.\thanks for any ideas...

This a thread by poorman9 with a bike that inspired him, and just about anyone that looked at it. the side panels are great.http://www.xs650.com/forum/showthread.php?t=10291&highlight=poorman9&page=3

This is what I did with some aluminium
Like what jmarkha1 said, lots of templates and lots of imagination.

Good luck with it.

xsPete · Apr 29, 2012

Try and attach my pics this time :banghead:

I had to mount my coils down the back because of the tank i'm using and the green coils are too ugly to be seen in public.

jmarkha1 · Apr 29, 2012

thanks guys - loving the drilled, curved panel xsPete - nice work there.

I started today so will start a build thread.
Got all the lugs off frame and made some cardboard templates taped up - then transferred to 3mm MDF which is just pliable.
Next - will weld some dzus tabs to back of frame and wet the MDF (thx for that idea yamaman).
Will get some 2mm alloy and replicate - will also need to add a couple of scoops to clear the XS filters - and either polish or paint.
more to come...

WacoBrian · Apr 29, 2012

here are some crapy ones i thou together out of stainless

jmarkha1 · Apr 29, 2012

looks good Brian :thumbsup:

dahondaboy · Apr 29, 2012

not a tracker but finished these panels last night. left side mounted solid, right side is bolted on for fuse access. cardboard is definitly the way to go and cut big first. you can always remove material but not as easy to add it . good luck!

:thumbsup:

jmarkha1 · Apr 30, 2012

Made a start on side panels with cardboard - several attempts to get a good fit prior to the MDF.
Also made up a mild steel mount for battery box and electrics, using the standard rubber mounts.
next - time to weld on dzus tabs and line everything up - a few other pics of little projects too...

managed to take apart the speedo and install a green and blue led for neutral and hi beam.

Found a very neat switch control that handles lights, kill switch and horn - originally fitted to KTM 450EXC & 520s around 2005. I have part numbers and wiring into XS650 if anyone is interested - cost around Â£35.00 inclusive.

dahondaboy · Apr 30, 2012

i am sooooooooo interested in that switch please post the diagram/wiring info

jmarkha1 · Apr 30, 2012

KTM part number: 50311070000
Part name: H.LIGHT SWITCH CEV 2/4TAK
Wiring Diagram: http://img196.imageshack.us/img196/8318/wiring.jpg

very nice quality and waterproof...should get one via any KTM dealer.

jmarkha1 · Apr 30, 2012

A bit more info on the wiring diagram:
Towards the top left of the diagram there is an item called "high/low beam switch.." - that's the switch.
Wires:
white - side light
brown - earth
red - horn
blue - high beam
yellow - connect to positive power from generator that powers the front and rear brake light switches
green - main beam
yellow / black - kill circuit (wiring tbd CDI or earth)

Phyberoptic · Apr 30, 2012

-=PO

jmarkha1 · May 1, 2012

Looks really nice Phyberoptic -

Ccrider · May 1, 2012

Good stuff..
What you have for switches on the other side ?

dahondaboy · May 1, 2012

thank you for the switch info, and @ ccrider, looks like theres nothing else you need if its a kicker only.

shaas · May 1, 2012

Here is my attempt in aluminum. They are fitted over the stock battery/electrics box.

dahondaboy · May 1, 2012

shaas said:
Here is my attempt in aluminum. They are fitted over the stock battery/electrics box.QUOTE]

Shiny! and nice bend in it. great job.

jmarkha1 · May 1, 2012

very nice shaas...
what shocks are you running?

XStretchified650 · May 2, 2012

I am going to use the stock air boxes, this is what I came up as a tweak for the side covers. The tins will get painted but the grills will have the stainless steel finish.

Shaas...looking good, do you have a photo from a forward angle?

Making custom side panels - any ideas?

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