July 3rd, 2011, 08:44 PM | #1 |
Tightwad Tinker
Name: Hans
Location: Lexington, Ky
Join Date: Apr 2011 Motorcycle(s): '09 Ninja 250R Posts: 161
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Wanted: HOWTO make better fairings for under $100
I hate the stock fairings. They're pretty, but I hate them, hate them, hate them! They make maintenance a total PITA. You can't attach clip-ons where YOU want them. Those !@#$%^ round plastic pins break. Fairings scratch easily. Many add-ons require workaround engineering because some dumb piece of cheap plastic is in the way. Replacements are so out-rage-ous-ly overpriced that using duct-tape is pretty much the only option if you already have a 2nd mortgage and don't want to start moonlighting as a prostitute.
Fairings are supposed to keep water and dirt out, but the stock ones don't do a good job. Instead they collect dirt in general and collect sand in that spot right behind the windshield to be specific. So, anybody here tried something like the following with any success? BLACK ABS SHEET 48x96x0.06" KEVLAR FABRIC - K49 Style 353 x 50" Kevlar Cloth The idea would be to triangulate the surface with pre-cut ABS parts using a saw and plastic welder, glue on the fabric (definitely makes nicer edges) and possibly shape some finer details with a heat gun. Kevlar breaks down under UV, but can be prevented by a simple layer of paint. The fabric should prevent visible cracking and most scratches should be able to be fixed by applying more paint. Maybe the following equation is true: speed-freak + golf-ball = dimpled fairings. |
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July 3rd, 2011, 08:49 PM | #2 |
wat
Name: wat
Location: tustin/long beach
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i had always thought fairings were to help with wind resistance...
have you tried riding without fairings?
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July 3rd, 2011, 09:18 PM | #3 | |
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Name: Cody
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Quote:
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July 3rd, 2011, 10:02 PM | #4 | |
Tightwad Tinker
Name: Hans
Location: Lexington, Ky
Join Date: Apr 2011 Motorcycle(s): '09 Ninja 250R Posts: 161
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Quote:
Not to mention that breaking any of the inside parts is more likely to total the bike. In your experience is getting a 2nd mortgage an even larger pain in the ass than -- ahem, using inappropriate metaphors? |
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July 4th, 2011, 02:07 AM | #5 |
ninjette.org certified postwhore
Name: Rick
Location: Alexandria, Louisiana
Join Date: Jan 2009 Motorcycle(s): 05 Blue Ninja 250 Posts: Too much.
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Sounds like a great idea for customizing your bike. Give it a try and let us know how it goes. I look forward to seeing some pics of your work and a DIY from you to help others do the same.
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July 4th, 2011, 12:19 PM | #6 |
Ninjette wanabe :D
Name: Ruslan
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the 250 is one of the sexiest bikes if you dont like it ill happly take it x]
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July 4th, 2011, 12:40 PM | #7 | |
KThanksBye
Name: Kevin
Location: Orange County
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Quote:
Your bike is definitely broken, please send it to me
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July 4th, 2011, 01:01 PM | #8 | |
Tightwad Tinker
Name: Hans
Location: Lexington, Ky
Join Date: Apr 2011 Motorcycle(s): '09 Ninja 250R Posts: 161
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Quote:
Unfortunately for you guys my bike is not broken, but the stock fairings seriously limit the options for adding a turbocharger. As far as I'm concerned the technical stuff and safety come first and appearance comes last. |
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July 4th, 2011, 01:40 PM | #9 |
KThanksBye
Name: Kevin
Location: Orange County
Join Date: Mar 2011 Motorcycle(s): 2006 zx636r Posts: A lot.
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Then maybe you need a different bike? I hear that Suzuki makes some cool bikes that go really fast and look good
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July 4th, 2011, 01:44 PM | #10 |
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I had no trouble adding clip-ons with the stock plastic. But removing the top of the fairing will give you lots of room. Removing all the plastic is the cheapes thing to do. Just change the tank for a used one from something else.
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July 4th, 2011, 03:27 PM | #11 | ||
Tightwad Tinker
Name: Hans
Location: Lexington, Ky
Join Date: Apr 2011 Motorcycle(s): '09 Ninja 250R Posts: 161
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Quote:
Quote:
It takes two seconds to pop the hood of my car and I really wish I could do the same thing on my bike. I can't believe that there is absolutely no way of achieving this. Velcro is cheap, easy to replace, doesn't rust, can't fall down a drain, can't be stripped, doesn't need to be torqued, won't rattle, and a square foot of the stuff holds over 6,000 lbs. |
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July 4th, 2011, 11:50 PM | #12 |
wat
Name: wat
Location: tustin/long beach
Join Date: Sep 2009 Motorcycle(s): wat Posts: Too much.
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i'm still lost on where using abs and kevlar is cheaper or results in a better quality product than fiberglass or even straight abs... or how it is more resistant to the paint on the surface scratching and why you can't "just add more paint" to fiberglass or abs... or how it protects the inside of the bike better which is supposed to get air flow... or how it makes it easier to get on or off?
i'm curious to see the result of your writeup
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July 5th, 2011, 10:02 AM | #13 | |
Tightwad Tinker
Name: Hans
Location: Lexington, Ky
Join Date: Apr 2011 Motorcycle(s): '09 Ninja 250R Posts: 161
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July 5th, 2011, 10:05 AM | #14 |
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July 7th, 2011, 05:34 AM | #15 |
ninjette.org member
Name: Bob
Location: Centreville va
Join Date: Sep 2010 Motorcycle(s): 1991 EX500 , 2009 250r Posts: 130
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I like the idea.
Shave down some weight, faster removal, lower maintenance, and lower cost. Sounds like a win to me. Also by stretching kevlar over the abs you mean leaving the kevlar unsealed? so with a slight texture? I wonder if that would help air flow? Like the textured paint on a sub. I've been toying with the idea of getting a pregen ex250 and fitting a vintage race fairing to it with a cafe seat. Give it that vintage look and hopefully some good aerodynamics as well. The goal for that bike is a 70+ mpg bike. I'm really aiming for 100 mpg but baby steps I know that the pregen is fairly aerodynamic already but it is 80s ugly. The full old RD vintage fairings are much cooler looking. Bob |
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July 7th, 2011, 08:13 AM | #16 |
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Name: Joe
Location: Buffalo NY
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Buy quick change quarter turn fasteners to replace the stock bolts.
http://www.dzusfasteners.net/ They're for making fairing ins/removal much faster. http://www.racebolts.com/index.php?m...ndex&cPath=723
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Last futzed with by Buffalony; July 7th, 2011 at 08:42 AM. Reason: 2nd link |
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July 7th, 2011, 10:43 AM | #17 |
ninjette.org member
Name: temps
Location: canada
Join Date: Feb 2011 Motorcycle(s): 2010 250 ninja Posts: 21
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I would go with fiberglass.. fiberglass cloth is pretty cheap. The hard part would be getting in the right shape you want..if you googled how to make a fiberglass boat hull they would probably have instructions on making a mold that would be removed after the glue dries.
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July 7th, 2011, 11:24 AM | #18 |
ninjette.org member
Name: Fred
Location: Brazil
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Master Yoda says: "Anger leads to hate. Hate leads to suffering.”
Anger I fell in you.
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July 13th, 2011, 04:08 PM | #19 | ||
Tightwad Tinker
Name: Hans
Location: Lexington, Ky
Join Date: Apr 2011 Motorcycle(s): '09 Ninja 250R Posts: 161
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Quote:
Quote:
So, IMHO, maybe, maybe not, but definitely not: definitely not. Last futzed with by Lowspeed Lowside; July 13th, 2011 at 07:33 PM. |
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July 13th, 2011, 04:43 PM | #20 |
ninjette.org certified postwhore
Name: Rick
Location: Alexandria, Louisiana
Join Date: Jan 2009 Motorcycle(s): 05 Blue Ninja 250 Posts: Too much.
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Thanks to your thread I have been inspired to go on-line and look up DIY's on using moldable plastic. I want to make my own rear tire hugger since there is not one commercialy available for the pregens. Wish me luck.
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July 13th, 2011, 05:28 PM | #21 | |
Tightwad Tinker
Name: Hans
Location: Lexington, Ky
Join Date: Apr 2011 Motorcycle(s): '09 Ninja 250R Posts: 161
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Quote:
You might find the following advice helpful on your quest...
Last futzed with by Lowspeed Lowside; July 13th, 2011 at 09:39 PM. |
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July 13th, 2011, 05:47 PM | #22 |
ninjette.org certified postwhore
Name: Rick
Location: Alexandria, Louisiana
Join Date: Jan 2009 Motorcycle(s): 05 Blue Ninja 250 Posts: Too much.
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Thanks Hans. Great advice. I also believe in the concept of KISS
Keep It Simple Stupid |
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July 14th, 2011, 05:02 PM | #23 |
Tightwad Tinker
Name: Hans
Location: Lexington, Ky
Join Date: Apr 2011 Motorcycle(s): '09 Ninja 250R Posts: 161
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KEVLAR FABRIC ® 54" WIDE aprox. 6.25 oz sq yd FULL ROLL
I thought what the heck and bought a 54"x72" piece of the stuff for $63.90 shipped. As far as I can tell that's about 3x the price of fiberglass fabric, but should be sufficient material to make two complete sets of fairings. A gallon of Bondo Interior/Exterior All-Purpose Fiberglass Resin is $35.98 at Lowes, but is this stuff suitably elastic? What are the chances of success by simply applying a thick layer of paint such as: http://www.homedepot.com/Rust-Oleum/...atalogId=10053 |
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July 14th, 2011, 06:20 PM | #24 |
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July 14th, 2011, 07:35 PM | #25 |
Tightwad Tinker
Name: Hans
Location: Lexington, Ky
Join Date: Apr 2011 Motorcycle(s): '09 Ninja 250R Posts: 161
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ABS PLASTIC PELLETS BLACK/COARSE 4 lbs FREE SHIPPING: $20.00 shipped.
Let's try dissolving ABS pellets in acetone and use that to glue/fix the fabric. If that doesn't work, we might be able to use the fact that ABS melts at ~105°C whereas Kevlar remains moderately stable until 260°C. Of course, I should have checked whether it is a known fact that ABS is repelled by or dissolves Kevlar... |
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July 14th, 2011, 08:03 PM | #27 | |
Tightwad Tinker
Name: Hans
Location: Lexington, Ky
Join Date: Apr 2011 Motorcycle(s): '09 Ninja 250R Posts: 161
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Quote:
If we're using heat we could use Reynolds instead of Saran wrap, but of course I'm open to any other seemingly loony suggestion. |
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July 14th, 2011, 09:33 PM | #28 | |
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Name: Joe
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Quote:
Carnuba wax and PVA? http://www.hotrod.com/howto/60478_fi...all/index.html
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July 15th, 2011, 12:30 AM | #29 | |
Tightwad Tinker
Name: Hans
Location: Lexington, Ky
Join Date: Apr 2011 Motorcycle(s): '09 Ninja 250R Posts: 161
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Quote:
I like the idea of using Pam and/or wax paper as mold release agents. |
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July 15th, 2011, 08:32 AM | #30 | |
ninjette.org certified postwhore
Name: Joe
Location: Buffalo NY
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Quote:
When the panels are finally all buttoned up, they're nice and firm though. It still bothers me that there is non uniform stresses in them. This winter I'm going to pull things apart and start at the front. Just go through aligning everything. I think I'll take some pics and post a DIY if things are succesfull. I believe it would make things a little quicker for me and tighten up the look some without this issue. Adding 1/4 turns is also on my list. On your existing fairings, maybe body putty for adding small features and styrofoam temporarely for larger ones. Using a saw for new openings. Then do your glass or kevlar overlay right over that.!! I'm not sure of exactly what your trying to accomplish. This thread interest me because I really love some and hate other lines on this bike. Mainly Im not too fond of the long horizontal line.
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July 18th, 2011, 05:14 AM | #31 |
ninjette.org sage
Name: Matthew
Location: Toronto
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This thread has me considering buying a bunch of colored carbon fiber...
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July 18th, 2011, 12:40 PM | #32 |
Tightwad Tinker
Name: Hans
Location: Lexington, Ky
Join Date: Apr 2011 Motorcycle(s): '09 Ninja 250R Posts: 161
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The Kevlar and ABS pellets just arrived. The fabric is so thin and light that it's hard to believe that it can stop a bullet. Needs ironing or something to get rid of the creases.
The cost of ABS cement is roughly the same as dissolving the pellets in MEK or acetone, so we're unlikely to save much by mixing it ourselves. See: http://www.mp3car.com/fabrication/10...s-plastic.html The whole technology isn't new, so I'm actually a little surprised that people aren't selling off the stock fairings and that there aren't hundreds of designs with downloadable sewing patterns. Instead of using a mold, we should consider using a simple wire frame with few vertices and let the fabric assume an approximate minimal surface like a soapy film.
Last futzed with by Lowspeed Lowside; July 21st, 2011 at 05:17 AM. |
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July 18th, 2011, 05:12 PM | #33 |
ninjette.org certified postwhore
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July 18th, 2011, 05:45 PM | #34 |
wat
Name: wat
Location: tustin/long beach
Join Date: Sep 2009 Motorcycle(s): wat Posts: Too much.
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iirc they use between 13 to 30 layers of kevlar depending on application with varying weave direction in bullet-proof vests
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July 18th, 2011, 06:16 PM | #35 | |
Sexy Beast
Name: Mat
Location: Tampa
Join Date: Mar 2011 Motorcycle(s): 2010 Ninja 250R, 2006 ZX-14, 2012 Ducati Monster Posts: A lot.
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Quote:
my bike; |
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July 18th, 2011, 07:10 PM | #36 |
Name: ...
Location: ...
Join Date: May 2009 Motorcycle(s): ... Posts: 999
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Ouch
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July 18th, 2011, 07:48 PM | #38 |
GDTRFB
Name: Drew
Location: SE PA
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I think that kkim has already cornered the market on all broken Ninjas. You must pay to have it shipped to Hawaii.
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July 18th, 2011, 08:40 PM | #39 |
The Corner Whisperer
Name: Chris (aka Reactor)
Location: Northern KY
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Interested, thought about this myself for the 91 ninja
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