hood

As I mentioned previously,I replaced the hood while I was installing the PA kit. I don't have many photos, but basically I drilled out the over 150 rivets ,removed the hood, and placed it on a piece of particle board 4 feet square, on top of the sheet of new material. I then cut a piece of plywood to put on top that covered the entire surface, leaving just enough room to drill through all the holes in the old hood. I then applied all the weight I could find to flatten the hood, and taped it down with wide scotch tape. I drilled through all the holes, then marked the outline with a scribe, which simultaneously cut the tape. I also traced around the old hood with a sharpie, which gave me a more visible line for sawing the piece on the bandsaw. After roughing it out on the saw, I filed the entire perimeter down to the scribe line.

I constructed a makeshift table the same heighth as the band saw, so I could manipulate the workpiece while still being close enough to see what I was doing.

I also made up a simple jig to prebend the hood, so it wouldn't be as stressed as the first piece that I had forced into place without pre-bending. It was alot of work, but the sheet of Al. was only $100.00 and I was pleased with the results. Having the hood off made it easier to install the wiring for the motor as well. I did a few other things while I had it back down the basement.

Previously the handlebar had been restrained by a piece of coathanger that swiveled out of the way, which you sometimes hit your knee on, and which frequently allowed the handlebars to get away, slamming the cyclocomputer into the seat. I simply made an Al bracket with a v shape to trap the ends of a loop of bungee cord, and riveted it to the dashboard. It works great, ...the handlebar is always secure.

This is an Al. peg that I tuned down on the lathe to attach the bungee cords on the canvas cover to. The cover came with white plastic screws for this purpose, and I didn't like the way they looked. I drilled and tapped the pegs, and used 5mm bolts with washers from the inside of the vm to attach them. Another task was the design and construction of a trailer hitch.

I drilled and tapped two 6mm holes in the swing arm, and bolted the hitch on. Since the swing arm is steel, I can always weld a couple nuts on if the threads pull out of the square tubing. It seemed like there was enough meat there, and so far it's been fine. You can see all the aluminum dust on top of the swing arm from filing the required clearance for the trailer. I used the pattern from the other side for the click box, and just kept enlarging it till I was sure the trailer couldn't hit the side of the tail.