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  • #1

    side cover mold

    I've been thinking...

    Why dont I make a mold to make new fiberglass side covers?

    Because I don't have an original side cover to make a mold out of. If anyone has originals and would be interested in taking part in this task. I would make the mold with your side covers and send them back to you in the exact same condition I got them in. I would pay for shipping both ways and I would also provide you with replacement covers for free, as long as I am able to get this to work successfully.

    It could be done as a winter project so noone would have to be out their side covers during riding season.

    JAT

    Or if anyone is doing this already..let me know...

    Cheers!!
    Last edited by mrdigitech; 07-08-2011, 10:13 AM. Reason: forgot to add
    1979 XS 1100F
    Daily Rider
    DIY'r
    Minneapolis,mn
    Tags: None
  • #2
    I can see the covers being copied but what about the attachment points? Especially the locking post? Is that doable in fiberglass molding?
    79SF
    XJ11
    78E

    Comment

    • #3
      And also, how experienced are you at making molds? This is a possibility for me, but i would like to know my originals will come back in one piece.
      1980 XS1100LG Midnight
      1991 Honda CBR1000F Hurricane


      "The hand is almost valueless at one end of the arm if there be not a brain at the other"

      Here's to a long life and a happy one.
      A quick death and an easy one.
      A pretty girl and an honest one.
      A cold beer and another one!

      Comment

      • #4
        If you're serious about doing this, I've got pair of '78-79 standard covers I could send you (the 'back up' set if my good set gets damaged/lost). The left side has the usual missing latch tab, and the right has a small piece missing but they're otherwise intact. To duplicate the other years/models, you would only need a set of '80-81 special covers, and a pair of '79 Special or '80-81 standard covers as these are shaped the same, the difference being the mounting slots/holes in the left cover. Mold that with no holes/slots, you could cut to fit.

        I assume that you're not going to try to cast the latches, but simply the outer shell. Maybe adding a 'tab' to the right side cover to make attaching to the bike would be a help.
        Fast, Cheap, Reliable... Pick any two

        '78E original owner - resto project
        '78E ???? owner - Modder project FJ forks, 4-piston calipers F/R, 160/80-16 rear tire
        '82 XJ rebuild project
        '80SG restified, red SOLD
        '79F parts...
        '81H more parts...

        Other current bikes:
        '93 XL1200 Anniversary Sportster 85RWHP
        '86 XL883/1200 Chopper
        '82 XL1000 w/1450cc Buell, Baker 6-speed, in-progress project
        Cage: '13 Mustang GT/CS with a few 'custom' touches
        Yep, can't leave nuthin' alone...

        Comment

        • #5
          I have made a few molds back years ago. I would say I'm not an experienced molder but with patience and using my old man's wise words in response to the ultimate question "How did you do that?!" he would say "very carefully"

          The tabs and mounting points would have to be built up after the outer shell is complete.

          I could make the molds out of cracked or slightly damaged side covers. Missing mounts or cracked mounts would not be a concern. Actually maybe ones with missing tabs would be best...

          I've been thinking about this for quite some time, just never had any side covers to replicate. I'm going to do it with my bag lids this winter because i've heard they get lost/cracked sometimes. And I do have a set of bags from my PO who lost the lids.

          I'm out of town for the weekend but will be back on this Monday.

          Cheers to all!
          1979 XS 1100F
          Daily Rider
          DIY'r
          Minneapolis,mn

          Comment

          • #6
            I have a few extra 79 standard and special covers (off the parts bikes) you could borrow.
            1979 xs1100 Special -
            Stock air box/K&N Filter, MAC 4-2 exhaust, Bad-Boy Air horn, TC fuse box, Windshield, Soft bags, Vetter Fairing, Blinkers->Run/Turn/Brake Lights, Headlight Modulator, hard wire GPS power

            Short Stack - 1981 xs1100 Standard - lowered for SWMBO.

            Originally posted by fredintoon
            Goes like a train, corners like a cow, shifts like a Russian tractor, drinks like a fish, you are gonna love it.
            My Bike:
            [link is broken]

            Comment

            • #7
              I have my doubts that fiberglass would be strong enough to fab the latch pins, plus the difficulty of molding the shapes. But that shouldn't be a deal-breaker; any kind of reproduction sidecover should be welcome.

              As far as attaching a 'generic' cover, it wouldn't be a big deal to come up with a simple attachment that would work. If you wanted to get fancy, you could go with a Dzus fastener (like these: http://www.dzusfasteners.net/categor...?sort=priceasc), but a simple hairpin cotter pin (like this: http://www.google.com/products/catal...d=0CFoQ8wIwAg#) could be used ala like the old 'hood pins' popular in the 60s. You could find these at nearly any hardware store.
              Fast, Cheap, Reliable... Pick any two

              '78E original owner - resto project
              '78E ???? owner - Modder project FJ forks, 4-piston calipers F/R, 160/80-16 rear tire
              '82 XJ rebuild project
              '80SG restified, red SOLD
              '79F parts...
              '81H more parts...

              Other current bikes:
              '93 XL1200 Anniversary Sportster 85RWHP
              '86 XL883/1200 Chopper
              '82 XL1000 w/1450cc Buell, Baker 6-speed, in-progress project
              Cage: '13 Mustang GT/CS with a few 'custom' touches
              Yep, can't leave nuthin' alone...

              Comment

              • #8
                I have a set of clean, straight, no chips or cracks, and all tabs intact 78's, that I would allow the use of for your winter project.

                I'd box and pay ship to you, you use my boxes, and packing, pay for the return. You could put the shells in the same boxes. Just need the shells you produce, let me worry about the mounting tabs. I've got some ideas about improving those anyway.

                When you get back, let me know if this would work for you. And we can go from there.

                Doo-Daa

                Comment

                • #9
                  Do a search of old threads. This has been attempted before by others, including me, with varying levels of success. My attempt was with carbon fibre, and for the most part was successful, until i tried to mount it. Get one of those silicon molding kits and cast the mounts and latch out of 'poxy resin, then figure out how to attach them to the cover.
                  1980 SG. (Sold - waiting on replacement)
                  2000 XJR1300. The Real modern XS11. Others are just pretenders.

                  Woman (well, my wife anyway) are always on Transmit and never Receive.

                  "A man should look for what is, and not for what he thinks should be" Albert Einstien.

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                  • #10
                    This would be cool to use. I have seen them in action. Pretty pricey but very cool.

                    The scanner to copy the original: http://www.nextengine.com/

                    The printer to make the copy:

                    http://www.dimensionprinting.com/app...mechanics.aspx
                    1979 XS1100F (runnin the wheels off it)
                    1979 XS650 (ran the wheels off it)
                    1976 CB550F (ran the wheels off it)

                    Comment

                    • #11
                      I have a buddy in Mn that rebuilds xs11 one after another. I'm sure he would love to have a way to get new side covers. He in Milaca...I think that's how you spell it..he'd like to help..I'm sure....Anyway I have an xtra 79 special left side cover and a few 78/79 standard covers in semi broken state....the lock tabs are snapped. You could have them. As long as you are going to fab a new cover maybe think about a set that fits just inside the frame bars and doesn't stick out so far. I know when people put pod filter on it always looks od to have the side covers come up so far and just hang there in space.
                      It sounds like a great idea to me. I think you could make a job out of new side covers, custom seats and exhausts for these old dogs. PM me your shipping info and I'll send them.
                      79 XS11 Special (Lazarus)
                      80 XS850 Special (Old Faithful)
                      80 XS11 Standard sorta stock (Beatrice)
                      79 DT 100

                      Comment

                      • #12
                        They've started this sort of thing in the UK, using injection moulded plastic. I've not found and XS1100 one but here's ones they're doing for the CBX. Iwould have thought they'd do the XS1100's easily enough maybe?
                        http://cgi.ebay.co.uk/CBX-1000-LH-Si...item3f0afe934a
                        XS1100F 1980 European model. Standard. Dyna coils. Iridium plugs. XS750 final drive (sometimes). Micron fork brace. Progressive front springs. Geezer regulator/rectifier. Stainless 4 into 2 exhaust. Auto CCT (Venturer 1300) SOLD. New project now on the go. 1980 European model.

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