It was early spring when we had a call from a gent about doing some custom work on a Suzuki GSXR. He wanted to give his side panels that Yoshimura look. The out line was would we be able to make a series of air vents and weld them into the side panels. I was more than interested as one of my first custom jobs was a GSXR of roughly the same year. So I have a bit of a soft spot for these bikes.
Over the weeks that followed it became clear that there was not the budget needed to allow us to fabricate the vents from plastic and weld them in, as the customer wanted. Which was a shame! When it comes to making parts from scratch it is labour intensive. But all was not lost the customer had discovered a set of fibre glass vents that matched what he wanted to achieve and asked us if we would be able to make them fit.
After some weeks the vents turned up at the workshop and with a bit of trepidation I opened the package. I have nothing against fibre panels but I have seen some really bad ones. These surprised me, they had a quality finish and looked the same size. On very careful inspection one was slightly smaller than the other and they curved more than the panels they were being fitted into; which in the end lead to an over complicated fitting arrangement.
Once the holes were cut to shape in the side panels, some plastic material was cut to fill the gap left by the original vent. Then a lip was cut into the plastic where the new fibre vents would sit. If they had not been made with an exaggerated curve this part of the job would not have been necessary. It took two of us to bond each vent into place. When this was set the vents were then fibre glassed in with a water proof matt to stop weather degradation. When the fibre glass was dry we used a special flexible filler to fill between the two materials to reduce the chance of cracking.
It is always nice to hear that the customer is happy with the results especially when it is done long distance.
Lets hope there is a change in the weather soon.
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