Who needs side covers?

[fabricgator]

I talked to a colleague the other day regarding the need for side covers for our cycles.

Zach and I, we are professional builders of composite aircraft. I more the mechanic and airframe guy and Zach, he is the composites genius. He currently has designed and manufactures several parts for a particular airframe.

So I was watching him as he was releasing some parts out of a mold, and asked him about making side covers for the XS 11's

I have a set from my 79 SF that are in good shape, with locking and attach spurs intact. He said we could make a set from mine without damage to my stellar paint job...

The first set is the most labor intensive, as the functioning mold must be fabricated. I am trying to get a feel for how many parts that could be made to supply a need to see if it is economically feasible.

Zach is a great guy, honest, reliable... I don't think he would be looking to make a killing, but he is a family man with a business to run.
Myself, I'd just be doing my part to help him find another product to make and to help you guys keep you bikes looking presentable...
I hope I never have the need to replace mine! (*DROP*) (*CRASH*)

So this is cards on the table:

• a) How many different styles are there?
• b) How many of you may be interested?
• c) Would you want them thin and light weight or closer to stock, thick and heavier?
• d) How many would you speculate could be needed in the community?
• e) What would you be willing for them to be worth?

I just mentioned this to him in passing last week. I need to show him my set so he can price them.

I am trying to see if there is an interest in them.

Let me know.....

[GARTHXS]

very cool

Bob Jones used to make fiberglass ones but they were prohibiting in cost

[Crazcnuk]

All the sidecovers, for the various years are essentially the same with respect to shape. There is, of course just a left and a right.

The only difference(s) that I know of are the mounting hole shapes. Some use round holes, some use slots. some have a combination of the two.

The bottom locking tab on the left side is the same for all years.

You should be able to make generic covers, and let the users put thier own holes in them.

A slight imprint of the various mount holes could be etched into the molds so that it would leave an impression for people to drill or dremel out.

[brcree]

Side covers.....

I sure need a set, but if theses are going to be alot more than I can get on ebay or craigslist...well............I hope ya'll can pull it together. Like to help out my fellow motorbiker.

[greatnw]

Well I know what I paid for mine.
Bought a right hand one for $15 and a left for $45. Both had badges that were in need of refinishing and both needed paint. ( I guess I'll get that done one day soon!)
I would think that $50 - $75 a set would be a brisk business. Maybe a little slower at $100.
Thanks for trying. Hope it works out!

[draketrumpet]

Well, the part of me that is in law school for the next two years will just get by with what I have unless its under $20, however...once I'm out of law school, as soon as I get a job that pays well, I want to do a proper restoration job and would be willing to drop a decent chunk if it was visually similar to the originals.

As far as construction, it's just got to be strong enough that you don't crack the right side when you're pulling the tab out or pushing it back in. I imagine your friend might be able to make something stronger yet lighter than the original, but I would probably focus on making it strong, functional and visually appealing for the lowest cost.

[freak_leg]

I'd definatly be willing to do $50 for a pair of covers. even if i have to paint them and drill a couple holes. I'v been thinking of doing something like this but dont have the equipment or a set of OE covers to make a mold, as i'm not willing to pay $100 - $200 a pair on ebay! As far as the constructon goes i'd definatly go with making them strong enought to stand up to being taken on and off a lot since i seem to spend more time taking parts off and on to fix random issues. Keep in touch if you get this rolling!!

[jwhughes3]

$60 a pair

I'd prefer stronger rather than lighter. I'd buy an extra pair to try out custom painting on.

John in San Antonio

[81xsproject]

The stronger the better. Weight isn't really an issue. It's plastic after all, how much could it weigh? I am glad to see someone else take interest in this. I pondered this for a long time as you could make some pretty good money off of this venture particularly on eBay. I didn't have the knowledge or the resources. If you were going to do one set, my personal feeling is that you should do late model ones that don't have all the funky corners, just nice smooth rounded curves all the way around. For the first time ever, probably I agree with the person above who stated that it would probably be best it you left the top holes out to be cut/drilled for the various different mounting options. I think $75 a set for primer ready would be more than reasonable (realistic). BJ wanted like $85 each for his fiberglass ones, but I don't think he sold too many as I have NEVER heard a member mention having a set.

[fabricgator]

Thanks for the input guys,

I went to see my buddy yesterday, but he is at the airshow in Lakeland.
I'll bring my set by his shop when he returns and will report back when I know more.

The reason I asked about the thickness is that the more layers, I'd imagine the more expensive. This would not be your typical fiberglass, nor would they be carbon fiber. I know that the parts he makes now are very strong and are lightweight. The thinner parts for airscoops are slightly flexible and the more layers get rigid... obviously.

From what I know of the process, and this is without consultation, the actual shape of the sidecover would be easily obtained. It seems to me that the mounting tangs could be a bit of challenge (at least for me). The buildup of the stud (tang) that either engages the lock mechanism or the rubber grommet on the RH side will have to be rigid enough to hold up to numerous installation and removals. Possibly even a cast or machined part that could be esthetically attached after the shape has been fabricated..... I'm just speculating here.... I'll have to talk with the master.

I know I had a RH side cover that was missing the tang or barb to engage the grommet. I made a barb with a SS 5/16"" pan head stove bolt that I double nutted onto the cover and finished that outside (visible) nut with a polished SS acorn nut. It was not perfect, but it sure was functional and socially acceptable.

Ideally, I'd like to see him be able to fabricate a set that is better than original, over coming the possibility of the mounting barb breaking or becoming worn, for an affordable price.....

[Ivan]

There are differences between special and standard and between years. As close as I can tell there are about six different kinds. Plus thr XJ.

[draketrumpet]

There are differences between special and standard and between years. As close as I can tell there are about six different kinds. Plus thr XJ.

While there are differences, are they all able to mount on the same spot?

[Guy_b_g]

Some use round mounting pins on the sidecover and use round holes with grommets to mount to the frame, some have oval holes and hang on wide "hooks" attached to the frame. Depending on the model they can either interfere with the seat, or leave a gap between the side cover and the seat. They also have somewhat different shapes.

[Guy_b_g]

Some use round mounting pins on the sidecover

My bad...should say "round holes", rather than "round pins" at the top of the sidecover..

[hightec_redneck]

hello everyone. I am new here, but just finishing my custom xs1100g up and modified the side cover mounting to be more secure, better fit, and more symetrical. If anyone is interested, I can explain and include pictures.