pa23driver
XS650 Addict
i was thinking about doing something with screens as well on my side covers, looks good XStretchified650
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Making custom side panels - any ideas?
XStretchified650
Back in the 650 Saddle
Thanks pa23driver...I wasn't sure about cutting up the the side covers, once I started though... it felt good.
RFLIVES
Resident Sidecar nut
I took round stock and made a wire frame first. Then tacked the sheet metal down while bending it to the curve of the wire frame, then buzzed the excess off with a cutoff wheel. Not sure if that makes sense but I got a cool battery box out of it. Holds a full size battery,tci,8 gang fuse box,starter relay,flasher and horn relay
jmarkha1
XS650 Member
very nice - how did you attach to frame? - welded tabs on frame?
Tron
Bearded Sheep Whisperer
RFLIVES
Resident Sidecar nut
Drilled holes on the bottom and tacked 1/4 20 nuts on the inside, welded a couple tabs to the frame with rubber washers insulating it.
good2bsims
XS650 Enthusiast
Try and attach my pics this time
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.
You got any pics of this set up? I was also thinking of mounting my coils back there in a box like that.
xsPete
XS650 Addict
Here's some pic's., as much detail as I've got.
It was the same deal, cut up a heap of cardboard trying to get the templates right, weld on tabs etc. I decided to go to bare aluminium, I just like the look of it.
Hope it hel
ps.Attachments
jmarkha1
XS650 Member
Just realized how old this thread is but have only just finished the bike and wanted to share what I ended up doing in the end.
I ran the bike without side panels for a while but did not like the look.
I managed to find a pair of 1970s side panels in ok shape and modified them to sit into the bike frame connected with stainless rods at the top edge and a welded nutsert in the lower frame - so they hinge out to get at the electrics.
Had to clearance the fronts for the carb inlets and added an ignition switch to tidy the wiring.
I ran the bike without side panels for a while but did not like the look.
I managed to find a pair of 1970s side panels in ok shape and modified them to sit into the bike frame connected with stainless rods at the top edge and a welded nutsert in the lower frame - so they hinge out to get at the electrics.
Had to clearance the fronts for the carb inlets and added an ignition switch to tidy the wiring.
.....................hi that yellow yamaha looks great regards oldbiker
-=PO
maine_buzzard
XS650 Member
Guess it's not a zombie thread, I'll throw in. Dzus fasteners work well, and the aluminum panels looked great on the Beast. I killed that bike and am now working on two XSs.
tstcin
XS650 Member
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 £35.00 inclusive.
That's what we use. Redneck CAD. Cardboard Aided Design.
