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 Complete side mount reg prep & install - 2009 Suzuki C800 / C50

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simbo
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PostSubject: Complete side mount reg prep & install - 2009 Suzuki C800 / C50   Thu Apr 18, 2013 9:39 pm

I started preparing the side mount reg plate holder for when I remove the indicator/reg thing and fill and respray the rear fender, First of all I got some black spray to match the bike so I could try it and make sure it was ok before painting the fender, 1 coat primer, 1 coat black and 2 coats of lacquer was enough just to try it. not the best spray job in the world but good enough for the back of the mount.



Next I drilled four holes in the mount, 2 for the led lights and 2 to feed the wires back behind the plate so they're out of sight, then fitted 3 washers between the plate and mount to give clearance for the wiring which comes out at the side and will be hidden along the false swing arm.

4 holes


washers between plate and mount

This is the plate with the led lights, I know they're to low but I used the existing reg and the holes were already there, any prob's next mot time and I'll get a couple of chrome ones and a new reg.


On the back where the wires and nuts for the light came through, I stuck 2 chromed spiked nut covers over them (I've used smaller ones than in the photo)


Next job will be to extend the wires and cover them with black heat shrink so they can be hidden more easily.





*************************************************************************

For extending the wiring I used a really old charger so it was quite long too, not like these modern 18 inch ones, I put the mount on tonight and removed the chrome thing, So now I'm at the point of no return! Gulp!!!





Next step is to cut 3 holes in the fender to remove the raised bits before filling and painting pale






*************************************************************************
The point of no return has been and gone now

After my morning ride of going here there and everywhere I ended up at Squires in Yorkshire and met Smart and Zen, Mick had just left, Anyway, back to the point of no return, when I got back I thought I'd take the plunge and remove the 3 raised points on the fender,

So out with the trusty Dremel (ok, industrial Dremel) to remove the lumps,

Lumps fully removed leaving subframe of fender on show, ready for filling with fiberglass and plugging the holes I'd just created,


I packed the fiberglass inside to make sure the fender grips the subframe and is held in place solidly,


I then sanded the fibreglass down where it was proud and give it a couple of coats of body filler,


Hopefully tomorrow? I'll sand it smooth and get a layer of fine surface filler on before priming it up to see if anymore filling is required?.

No going back now!


*************************************************************************

This morning didn't go as planned lol I got my palm sander out and started sanding away and the bloody thing blew up! sparks everywhere!
(note to self? need new palm sander) Back to basics it is then I sanded the filler back to smooth by hand (note pin hole top left and bottom right)


Next I gave it a coat of fine surface filler hoping to fill in any pin holes



Then after rubbing down with various grades of wet and dry sandpaper, I gave it a quick coat of high build primer.



I'm about 70% happy with it at the moment, The feel of it's good, but there's still a pin hole top left, I've filled it in now so hopefully the weather will be favourable this week and I'll get it finished off?



*************************************************************************
I've nearly finished now Very Happy I've just got the wiring to finish tomorrow, then it's back to ridable phew!!!






*************************************************************************
I wanted to use the standard indicators fitted to the rear fender bolt in this mod, but when I removed them, they have a rubber bung inside with no way of fitting them to anything other than the standard chrome thing they were on, So that's where the fun began :what1: I removed the rubber inner bung and got some m10 nipple tube and fitted it through the inside of the indicator.

Then I packed body filler around the tube inside the stem to hold it central and made a rubber washer to fit between the rail and stem, So I can mount the standard indicator anywhere now by drilling a 10mm hole.




*************************************************************************


This write-up has been consolidated from copied posts that Sim made throughout this entire thread
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twenty2
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PostSubject: Re: Complete side mount reg prep & install - 2009 Suzuki C800 / C50   Thu Apr 18, 2013 9:44 pm

Looks really nice.
Was thinking about uploading some pics of my side mount. But i think your guide is more than enough.
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simbo
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PostSubject: Re: Complete side mount reg prep & install - 2009 Suzuki C800 / C50   Thu Apr 18, 2013 10:13 pm

twenty2 wrote:
Looks really nice.
Was thinking about uploading some pics of my side mount. But i think your guide is more than enough.

Some pics would be nice if you could , It gives me idea's
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alfie92
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PostSubject: Re: Complete side mount reg prep & install - 2009 Suzuki C800 / C50   Thu Apr 18, 2013 10:24 pm

Looking good Sim,always nice to see pics.
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captain crash
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PostSubject: Re: Complete side mount reg prep & install - 2009 Suzuki C800 / C50   Thu Apr 18, 2013 11:07 pm

Excellent. very well thought out Simbo.
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twenty2
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PostSubject: Re: Complete side mount reg prep & install - 2009 Suzuki C800 / C50   Fri Apr 19, 2013 7:17 am

Hope this can give you some ideas Simbo, and ofcourse everyone elese.
This is how i solved my side mount.

1, Cut the pices that needed, one arm and one for the backside of the plate.


2. Messure where the arm should be positioned. I wanted mine to be slimmed so i let it "slip" over the swing arm for a bit. I allso made some angles in the bottom of the plateholder and at the bottom of the arm to make it stronger against bending forces.


3. Picture of assembled plateholder with holes drilled for the platem and allso for 2 diodlights.


4, Used the bottom bracket for the rearfender as mounting point.


5. Picture form the rear with mounted plate.
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captain crash
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PostSubject: Re: Complete side mount reg prep & install - 2009 Suzuki C800 / C50   Fri Apr 19, 2013 7:20 am

Good job twenty2, very close fitting & tidy
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fat intruder
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PostSubject: Re: Complete side mount reg prep & install - 2009 Suzuki C800 / C50   Fri Apr 19, 2013 9:33 am

both great bits of work cant wait to see the finished product sim
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simbo
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PostSubject: Re: Complete side mount reg prep & install - 2009 Suzuki C800 / C50   Fri Apr 19, 2013 5:57 pm

I'm just in the process of lengthening the wires for the led plate light, I'm right in thinking an old phone charger cable will be enough for two leds?
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captain crash
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PostSubject: Re: Complete side mount reg prep & install - 2009 Suzuki C800 / C50   Fri Apr 19, 2013 6:42 pm

Dave and Alfie were talking about that in another thread but I can't remember which one. Dave uses speaker wire and Alfie uses tellephone wire for LEDs, so yes that will be fine
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simbo
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PostSubject: Re: Complete side mount reg prep & install - 2009 Suzuki C800 / C50   Fri Apr 19, 2013 7:31 pm

Cheers Crash
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bigmal
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PostSubject: Re: Complete side mount reg prep & install - 2009 Suzuki C800 / C50   Fri Apr 19, 2013 7:42 pm

simbo wrote:
I'm just in the process of lengthening the wires for the led plate light, I'm right in thinking an old phone charger cable will be enough for two leds?

That's exactly what I used for the red LEDs in my panniers. The beauty of it is, you've got 2 insulated wires, then an outer insulation too, so it's well protected. There was a rating inkjeted onto the cable I canibalised, so I rang the LED supplier who recognised immediatelly what it was and said it was OK.

cheers
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simbo
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PostSubject: Re: Complete side mount reg prep & install - 2009 Suzuki C800 / C50   Fri Apr 19, 2013 9:19 pm

bigmal wrote:
That's exactly what I used for the red LEDs in my panniers. The beauty of it is, you've got 2 insulated wires, then an outer insulation too, so it's well protected. There was a rating inkjeted onto the cable I canibalised, so I rang the LED supplier who recognised immediatelly what it was and said it was OK.

Done it now Mal cheers It was a really old charger so it was quite long too, not like these modern 18 inch ones, I put the mount on tonight and removed the chrome thing, So now I'm at the point of no return! Gulp!!!Next step is to cut 3 holes in the fender to remove the raised bits before filling and painting pale



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fat intruder
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PostSubject: Re: Complete side mount reg prep & install - 2009 Suzuki C800 / C50   Fri Apr 19, 2013 10:10 pm

take it your foot boards tuch the floor before your numberplate just jokeing lol lookin goood
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bigmal
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PostSubject: Re: Complete side mount reg prep & install - 2009 Suzuki C800 / C50   Fri Apr 19, 2013 10:13 pm

Looking great so far Wink
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captain crash
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PostSubject: Re: Complete side mount reg prep & install - 2009 Suzuki C800 / C50   Sat Apr 20, 2013 12:43 pm

Love it, great jog Simbo cant wait to see it all finished
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simbo
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PostSubject: Re: Complete side mount reg prep & install - 2009 Suzuki C800 / C50   Sat Apr 20, 2013 10:03 pm

The point of no return has been and gone now After my morning ride of going here there and everywhere I ended up at Squires in Yorkshire and met Smart and Zen, Mick had just left, Anyway, back to the point of no return, when I got back I thought I'd take the plunge and remove the 3 raised points on the fender,

So out with the trusty Dremel (ok, industrial Dremel) to remove the lumps,

Lumps fully removed leaving subframe of fender on show, ready for filling with fiberglass and plugging the holes I'd just created,


I packed the fiberglass inside to make sure the fender grips the subframe and is held in place solidly,


I then sanded the fiberglass down where it was proud and give it a couple of coats of body filler,

Hopefully tomorrow? I'll sand it smooth and get a layer of fine surface filler on before priming it up to see if anymore filling is required?.

No going back now!
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captain crash
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PostSubject: Re: Complete side mount reg prep & install - 2009 Suzuki C800 / C50   Sat Apr 20, 2013 10:07 pm

Thats some scary shit your upto there Simbo, looking proper, cant wait til tomorrow to see the next installment Bit suprised your doing all this and going to spray it with the fender still on the bike but I am a kack handed twat and your not
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bigmal
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PostSubject: Re: Complete side mount reg prep & install - 2009 Suzuki C800 / C50   Sat Apr 20, 2013 10:25 pm

Wow, some serious stuff there SIM! Have you done much bodywork before? It would be sanding the whole thing to the right profile I'd find scary. Cant wait to see the end result...
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simbo
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PostSubject: Re: Complete side mount reg prep & install - 2009 Suzuki C800 / C50   Sat Apr 20, 2013 11:10 pm

Crash, Keeping the fender on is the best place to do the work for me, Plus I needed to refix it to the subframe with the fiberglass, I cover the rest of the bike up whilst working on it and when I get to spraying part, I'll make sure everything is protected before hand .

Mal, Err? bodywork Nah, but I've filled everything you can think of with various fillers before to good effect, So a bit of plastic doesn't really phase me lol Busy day tomoz (trip to Bangor again ) I've only got the morning to work on the bike, so hopefully all goes well, as I'm liking the rear fender more and more with nothing on it!, I did look at removing the rear light? but that is one seriously big hole!!
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fat intruder
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PostSubject: Re: Complete side mount reg prep & install - 2009 Suzuki C800 / C50   Sun Apr 21, 2013 8:16 am

proper job that (say it with a cornish accent) will look good when done mate and your bike is that much more your own
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Mr Intruder
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PostSubject: Re: Complete side mount reg prep & install - 2009 Suzuki C800 / C50   Sun Apr 21, 2013 6:40 pm

Looking really good Sim.
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alfie92
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PostSubject: Re: Complete side mount reg prep & install - 2009 Suzuki C800 / C50   Sun Apr 21, 2013 7:57 pm

Sound job that Sim,will look great when finished.
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simbo
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PostSubject: Re: Complete side mount reg prep & install - 2009 Suzuki C800 / C50   Sun Apr 21, 2013 10:11 pm

This morning didn't go as planned lol I got my palm sander out and started sanding away and the bloody thing blew up! sparks everywhere! (note to self? need new palm sander) Back to basics it is then :aghh: I sanded the filler back to smooth by hand (note pin hole top left and bottom right)

Next I gave it a coat of fine surface filler hoping to fill in any pin holes

Then after rubbing down with various grades of wet and dry sandpaper, I gave it a quick coat of high build primer.

I'm about 70% happy with it at the moment, The feel of it's good, but there's still a pin hole top left, I've filled it in now so hopefully? the weather will be favourable this week and I'll get it finished off.
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Mr Intruder
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PostSubject: Re: Complete side mount reg prep & install - 2009 Suzuki C800 / C50   Sun Apr 21, 2013 10:19 pm

Looking like you are so close, can't wait to see it all done Sim.
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Proudtexson
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PostSubject: Re: Complete side mount reg prep & install - 2009 Suzuki C800 / C50   Sun Apr 21, 2013 10:43 pm

Looking great. Wish I had that talent. Great job Sim
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fat intruder
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PostSubject: Re: Complete side mount reg prep & install - 2009 Suzuki C800 / C50   Mon Apr 22, 2013 8:37 am

looks good
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simbo
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PostSubject: Re: Complete side mount reg prep & install - 2009 Suzuki C800 / C50   Sat Apr 27, 2013 8:02 pm

I've nearly finished now Very Happy I've just got the wiring to finish tomorrow, then it's back to ridable phew!!!




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fat intruder
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PostSubject: Re: Complete side mount reg prep & install - 2009 Suzuki C800 / C50   Sat Apr 27, 2013 8:12 pm

fookin good that sim nice job pal
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Proudtexson
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PostSubject: Re: Complete side mount reg prep & install - 2009 Suzuki C800 / C50   Sat Apr 27, 2013 8:18 pm

Great Great job Sim. Very Pro Job
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Mr Intruder
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PostSubject: Re: Complete side mount reg prep & install - 2009 Suzuki C800 / C50   Sat Apr 27, 2013 8:21 pm

That looks brilliant Sim, first class job. You must be well pleased.
How did you feather in the clear top coat, or will you just wait a week or two and use a cutting compound?
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simbo
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PostSubject: Re: Complete side mount reg prep & install - 2009 Suzuki C800 / C50   Sat Apr 27, 2013 8:37 pm

Cheers guys Dave, I feathered it in just below the chrome fender rail, It needs a bit more work but I'll leave it for now,and just do bits over the summer.
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Mr Intruder
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PostSubject: Re: Complete side mount reg prep & install - 2009 Suzuki C800 / C50   Sat Apr 27, 2013 8:48 pm

That just looks so fekin good, so smooooooooooth.
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simbo
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PostSubject: Re: Complete side mount reg prep & install - 2009 Suzuki C800 / C50   Sat Apr 27, 2013 8:56 pm

I wanted to use the standard indicators fitted to the rear fender bolt in this mod, but when I removed them, they have a rubber bung inside with no way of fitting them to anything other than the standard chrome thing they were on, So that's where the fun began :what1: I removed the rubber inner bung and got some m10 nipple tube and fitted it through the inside of the indicator.

Then I packed body filler around the tube inside the stem to hold it central and made a rubber washer to fit between the rail and stem, So I can mount the standard indicator anywhere now by drilling a 10mm hole.

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pledge
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PostSubject: Re: Complete side mount reg prep & install - 2009 Suzuki C800 / C50   Sun Apr 28, 2013 10:19 am

Hi, Sim, I have to say I feared you had ruined you rear fender after you had taken the sander to it, but the job you have done is incredible it looks great, you must be delighted with the outcome, fantastic job well done mate.
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captain crash
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PostSubject: Re: Complete side mount reg prep & install - 2009 Suzuki C800 / C50   Sun Apr 28, 2013 10:59 am

The rear is looking brilliant Simbo
Good idea with the way you are making the indicators fit
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bikerdave
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PostSubject: Re: Complete side mount reg prep & install - 2009 Suzuki C800 / C50   Sun Apr 28, 2013 2:38 pm

Looks good Simbo. After seeing your pictures I need to chase mine up as it has been 2 weeks since I sent it off to be powder coated.
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alfie92
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PostSubject: Re: Complete side mount reg prep & install - 2009 Suzuki C800 / C50   Sun Apr 28, 2013 6:42 pm

Good job Sim,looks great m8.
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smart
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PostSubject: Re: Side mount reg prep.    Sun Apr 28, 2013 8:09 pm

Looks great good job Sim
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bikerdave
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PostSubject: Re: Complete side mount reg prep & install - 2009 Suzuki C800 / C50   Sun May 05, 2013 10:34 am

Got my bracket back from being powder coated. Copied the design from the one on Ebay but made it to my measurements for a good fit. LED number plate lights ready to go on. Just need to decide if i put a 8x6 or 7x5 plate on.

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JJW
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PostSubject: Re: Complete side mount reg prep & install - 2009 Suzuki C800 / C50   Sun May 05, 2013 1:00 pm

There are a lot of crafty people here.
Doing pro work, thanks for the pictures.
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simbo
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PostSubject: Re: Complete side mount reg prep & install - 2009 Suzuki C800 / C50   Mon May 06, 2013 11:20 pm

bikerdave wrote:
Got my bracket back from being powder coated. Copied the design from the one on Ebay but made it to my measurements for a good fit. LED number plate lights ready to go on. Just need to decide if i put a 8x6 or 7x5 plate on.

Looking good Dave I've got a 7x5.5 on mine with a fancy font if that's any use, I've not been pulled for it yet, but that's down to the local dibble in different area's.
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