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I'm a little late on this reply, but I've had good luck with sewing the foam on a sewing machine. Sorry, no picts, but adding a strip of fabric or backing on both sides will insure that the thread won't pull through the foam. Did this on my XS2 back in 2015 and after several cleanings in gas or Mineral Spirits, it is still holding up.Time to kill today so I started mounting / mocking a few parts up. Mounted battery box, inner fender, and rear fender. Threw a few parts on the frame to keep me inspired.
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Also put some attention to my air filters. The old foam was totally roached. One of the filter assemblies also came apart so needed glued back down. I tried some Gorilla glue and seems to be holding well.
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That deteriorated foam just disinterested when you look at it. I spent a little time cleaning it up before cutting new UNI foam to fit. I just need to glue the seams together. I can use the same glue, but that seem will turn rock hard. Anyone have suggestions for glueing the ends together? Overall I’m pretty happy with the results.
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The bike is looking good by the way!