Fiberglassing My Own Non-Exhaust Tail Section.

Fiberglassing Tail Project- Lights Added!

First off, I understand that many members of this community think that the VFR is the most beautiful thing on the planet. That may be true to an extent, but I am on the younger side (mid 20s) and have a knack for owning things with a certain degree of "unique". As a matter of fact, I bought the VFR because it brought a certain edge of unique that I really enjoy. My car is also modified to satisfy this urge-



This really came about because I rode several times with the cans off and absolutely loved the way the bike handled and pulled when it was missing that much weight so high on the body. I would have dropped the cans long ago but the tail section looks hideous without the exhaust to fill the large voids. Also, I felt that for a bike that was slow long and sleek it had a really fat rear end! The banana seat coupled with the width of the rear made it look like a fat pig sitting next to sportier bikes. Finally, I tossed a baffle into the cat when I fabricated a slash tip for it, and begun designing how I want the tail to go. Keep in mind, I am right now far from finished, but I can safely say that I am committed enough that I will follow through with it.

**I can go back to stock, although I cut out the heat shielding/plastic which would have to be reattached with a bonding method

****The finished product will still accommodate the passenger grab handles, OEM hardbags, both OEM seat +corbin seat+seatback

-Drew
This was the first look- tail section minus the plastics wrapped in fabric.



This is the tail with the frame work in place.
(wood is similar to wood dowel, but much thinner!)

Held together with hot glue


This is the framework along with the seat in place.



-Drew
This shot is with the initial coat of resin on the fabric- mocking up the grab handles.



After the initial coat of resin firmed up- I added pieces of glass just making it strong enough to detach.





-Drew


First coat of bondo (after several more coats of glass)


This is how it sits now- 3-4 coats of glass on bottom with two coats of bondo.


once I am satisfied with the bottom I will move to the top and work the top while its on the bike.

Thanks for looking
-Drew

 

You are a MADMAN, I like it :thumbsup:
Keep the report coming op2:

 

I dig it too. Look forward to seeing the end product.

 

Can you make me one also? what aboot the exhaust, do you plan on having it undertail ?

 

Faaaaack, yeah !!!

 

No I plan on working out a small set up to my liking. Right now I am adjusting the small baffle in my exhaust tip to get a sound I like. Nothing about this is to boost performance, if anything it may go down but the weight savings and look will hopefully make up for it. Worst case, I'll just run open cat and let that v4 howl...

 

Forgot one!



-Drew

 

Impressive work! Have you or a family member ever been into model aircraft?

 

No I haven't really... I started doing glass in car stereo stuff making flus speaker pods and using the glass to strengthen interior seams of subwoofer boxes. Currently I am a advanced composite maintainer on the F-22 so I get to dabble at work as well.

I actually have not! Now I will have to look into that! BTW- your 6th gen tail on 5th gen was very inspiring. I know the two projects are not the same- but it really got to thinking about how drastic the look can change with something as simple as swapping the rear.

-Drew

 

I like the design and am really curious about the construction details and technique. Years and years and years ago I attempted to designed a tail piece for my Guzzi. I almost went mad trying the get it perfect. The design was an attempt to mimic the tail on a Laverda RGS but it turned out a bit long. It was actually pretty practical with a huge storage space behind the pop in seat back. The seat was never right but was soft and really comfortable.

 

Nice work- cant wait to see other angles and paint matched!

 

Composite construction can be easy or a mofo. Best place to start is with a book. This one is good:

Composite Materials: Fabrication Handbook #1 (Composite Garage Series): John Wanberg: 9781929133765: Amazon.com: Books

Custom tail sections usually start with a positive. Typical is a semi closed cell foam positive.

Saves buying a 29lb. can of Bondo.

For advanced tech and more stuff check out - System Three Resins, Inc..

 

Slow and steady. I damaged the top portion during the re-install because the ragidity of thickening the bottom made it a pain to get on. Today's progress was reshaping the damaged portion and added several layers of glass reinforcement. Tomorrow I'll do another coat of glass, followed by the first coat of bondo up top so I can start shaping the lines to the seat and down around the footpegs.



Now that I am working 3-11 instead of night shift I am getting a serious itch to get back on the road.



-Drew

 

I am still VERY far from over.

But, I started work on the top this morning after doing the lawn work and before heading to work.







There are still pits/voids/out of contours but shooting everything with a light coat of black helps identify areas that really need attention. The downside being, now it becomes easier for the camera to pick up as well haha

-Drew

 

-Drew

 

I've finally gotten some time to reshape the point, as well as beginning the body lines.





And If I didn't already mention, I wear 100% gear when sanding.






Thanks for looking!!

-Drew

 

Oh man ! it is looking fkng good. Can't wait to see it painted. Congrats.

 

Night ride today.