Kawasaki Vulcan 800 Bobber Build – Final Touches...

At this time’s venture focuses on making essential adjustments to a Vulcan construct. Early within the course of, the crew discovered a difficulty with the gas tank that didn’t permit for correct coolant line clearance. To repair this, they selected to make use of a different tank that may match higher and permit the traces to run easily.

After updating the tank plan, the crew labored on mounting the seat and fender. They created sturdy brackets to ensure the seat and fender keep safe with out utilizing further struts. The subsequent steps embody placing again the facet covers and planning the exhaust pipes round these elements.

Key Takeaways

• The present gasoline tank wanted to be switched resulting from clearance points.
• Seat and fender mounting options had been custom-made for stability and elegance.
• Remaining steps will embody becoming facet covers and planning the exhaust.

Vulcan Fuel Tank Mounting Problem

Evaluating Excessive Mount and Center Mount Types

There are two principal sorts of tank mounts for the Vulcan: excessive mount and middle mount. The excessive mount has its mounting tab close to the highest of the tank, whereas the middle mount model locations the tab nearer to the center.

The tank purchased for this venture was a excessive mount mannequin.

Points with Coolant Line Clearance

With the high mount tank, the mounting tab will get in the way in which of the coolant traces operating underneath the body. The clearance isn’t sufficient, making it arduous to route the traces with out awkward changes.

A doable repair, like welding a bung, was thought of however didn’t look or match proper for this venture.

Steps for Changing the Gasoline Tank

As a substitute of forcing an answer, the present excessive mount tank can be stored for a special construct. The plan is to purchase a center mount tank in order that the coolant traces can correctly match beneath.

Subsequent Steps:

• Save excessive mount tank for later.
• Buy middle mount tank.
• Set up new tank, permitting area for coolant traces.

This strategy ought to preserve all the things neat and make future upkeep simpler.

Seat Mounting Options

Utilizing Pre-Drilled Holes for Seat Attachment

He began through the use of an present gap within the body to safe the entrance bracket of the seat. This technique helped anchor the seat while not having to drill new holes. By making use of what was already there, he saved time and stored the mounting process easy.

Including a Welded Cross Bar for Help

To carry the rider’s weight, a assist bar was welded throughout the mounting factors. This bar gave the seat a stable base and stopped it from sagging or shifting. The additional energy from the welded bar made the mount a lot sturdier.

Seat Help Overview:

Additional Bracket to Forestall Seat Shifting

To cease the seat from shifting facet to facet, he made one other bracket. This bracket connects from a gap within the body to the welded cross bar. Drilling a gap and bolting this bracket in place locked the seat so it stayed put. As soon as welded, the seat didn’t shift or wobble.

Attaching and Securing the Fender

First Fender Attachment Spot

The rear fender began with one mounting spot, positioned to maintain issues as regular as doable. There was no plan so as to add fender struts, so the look would keep clear and easy. So as to add extra safety, one other spot was chosen for a second attachment. This is able to make certain the fender doesn’t shift or shake whereas using. Utilizing two factors helps preserve all the things agency.

A fast listing of the steps for the preliminary mounting:

• Decide the primary spot for the fender.
• Bolt the fender down.
• Examine for motion and stability.

Welding the Facet Bung and Constructing the Second Bracket

For the second mounting level, a metallic bung was welded onto the facet of the fender. This small metallic piece allowed a bracket to be hooked up. The bracket, constructed from scrap materials, wanted to be drilled for a bolt. After shaping and drilling, the bracket related the fender to the body. Utilizing these two spots gave the fender strong support with out further struts.

Supplies Used

By taking these steps, the fender stayed agency and matched the straightforward look. No further assist rods had been wanted. Every thing lined up and stored the fender from shifting round.

Facet Covers and Pipe Adjustment

Placing the Facet Panels Again On

The subsequent step is to reattach the facet panels earlier than engaged on the pipes. That is essential as a result of it helps examine if the pipes will stumble upon the covers later. The side covers should be in place so you possibly can form and place the exhaust correctly.

Steps:

• Line up the facet covers with their mounts.
• Fasten them securely.
• Examine that all the things sits flat and doesn’t transfer.

Deciding on the Rear Exhaust Path

Earlier than constructing the exhaust, planning the route is essential. For the rear pipe, the plan is to have it exit and run underneath the plastic on the again. The plastic piece in the way in which will should be trimmed off. This provides sufficient room for the brand new pipe and avoids contact with the facet cowl.

Issues:

• The route should clear all different elements.
• The plastic blocking the pipe must be minimize.
• Double-check clearance from all panels.

Guidelines:

Subsequent Steps within the Construct

Tank Replace:
The present excessive tunnel tank can’t be used as a result of the mounting tab blocks the coolant traces. A brand new tank with a center mount can be ordered, so the coolant traces match beneath. The unique tank can be saved for one more venture.

Seat Progress:

• The entrance bracket for the seat makes use of an present gap for mounting.
• A support bar was welded to carry the rider’s weight.
• There may be one mounting level now, with plans so as to add one other utilizing a bracket from a gap to the assist bar, so the seat stays regular.

Rear Fender Work:

• The fender has one mounting level and wishes one other for further stability.
• To keep away from utilizing fender struts, a bung can be welded to the fender’s facet.
• A bracket can be made to bolt the fender down at a second level.

Facet Covers and Pipes:

• Facet covers can be reinstalled to examine pipe clearance.
• The rear pipe can be rerouted underneath the plastic, which must be eliminated to create space.
• Work on the exhaust pipes will proceed within the subsequent stage, ready for the brand new tank to reach.