New side covers - Honda Rebel Forum
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post #1 of 12 Old 01-25-2017, 05:22 PM Thread Starter
 
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New side covers

For whatever reason I have always hated the side covers on my 2008 rebel. Ever since I changed out the seat they just seem to stick out too far on each side.


I looked around the web and this site for a good while and the only option I could find for replacements was from Blue Collar and they were kinda spendy!!


I got the crazy idea to make my own. Having done quite a bit of leather work and holster making I was familiar with kydex and how to thermoform it.


I apologize that I didn't take enough pictures during the creation of this side cover but will try to outline my steps so that if anyone else wants to give it a try or improve on my idea you can.


1. I removed the old side cover and stuck it in the "back to stock" box in my work room.


2. removed the air cleaner housing cover and traced it onto a piece of paper. I wanted my new side cover to basically just cover the air cleaner. I also marked the holes on my paper template as I used the attachment holes from the air cleaner cover to attach the new side cover.


3. used the paper template to cut out a chunk of wood to form the kydex over. I drilled the holes for reference. You can see my wood mold in the pictures.


4. I took a square of that foam floor mat stuff and cut a hole a little larger than my wood block so that it would fit over and around the block.


5. Following the instructions on the kydex I heated it up in the oven then when it was flimsy I took it out (it is hot, use oven mits) and (quickly) layed it over the wood block (which I put on a board). Then (also quickly....this stuff cools pretty fast) I put the cut foam piece over the kydex and block and one flat piece of foam over the top. Then take another board and put it on top making a kind of sandwich.


6. You can find all kinds of videos of people making and using kydex forming boxes or jigs or whatever they call them. I just used two boards with the mold, foam and kydex between them. Rather than use clamps to secure the boards I just stood on them for about 10 minutes. (Then I opened the window....this stuff smells pretty bad when hot)


7. After opening taking the boards apart I had the almost entirely molded kydex side cover. To clean up some of the bends and make them tighter I used a heat gun and straight edge (metal ruler). I trimmed off the excess with a small exacto saw and sanded down the edges.


8. Drilled the holes and got longer bolts to fit the air cleaner cover. Also got some plastic spacers to fit between the air cleaner cover and my new side cover and there it is....


Weather has been pretty cold but I got a few rides in and everything is holding up and working great so far. Now to move onto the battery side...I have a couple ideas for that so we will see how it turns out.
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post #2 of 12 Old 01-25-2017, 05:27 PM Thread Starter
 
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the foam form

Here is what the foam looked like that I put over the kydex to bend it around my wood block. I made the hole a little too small and it fit a little too tight. Took some time to get it shoved down over the kydex and wood block. I think if the hole was a little bigger I wouldn't have had to use the heat gun to bend the sides down more.
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post #3 of 12 Old 01-25-2017, 09:23 PM
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nice work !

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post #4 of 12 Old 01-26-2017, 12:23 AM
 
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That's pretty nice work. I took a little simpler approach using the stock airbox cover.
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post #5 of 12 Old 01-26-2017, 10:53 AM Thread Starter
 
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Originally Posted by 01-7700 View Post
nice work !
Thank you. I am pretty happy with the outcome. Usually takes me 2 or 3 tries to get something the way I want it.
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post #6 of 12 Old 01-26-2017, 10:54 AM Thread Starter
 
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That's pretty nice work. I took a little simpler approach using the stock airbox cover.



Very cool! I thought about doing something like that too. The diamond plate is an awesome touch. Did your air cleaner cover have those vents in it stock or did you add them?
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post #7 of 12 Old 01-28-2017, 02:23 PM
 
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Very cool! I thought about doing something like that too. The diamond plate is an awesome touch. Did your air cleaner cover have those vents in it stock or did you add them?
If you look close you will see that they are located right where the tabs were that us snap the stock side cover on with. I ground each of them off and then used a hole saw on my drill press to make the holes for the UNI-vents. The diamond plate is spaced out away from the cover with red faucet washers and I used stainless steel allen bolts and copper washers on everything else to dress it up as much as possible.









Here's how I covered the battery side:
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post #8 of 12 Old 01-28-2017, 05:03 PM
 
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The air box is engineered to restrict the inflow slightly so that the box internal pressure is lower than outside atmospheric pressure and air flow velocity faster..

"Pressure Differential" and the fluid Velocity it creates is engineered into each engine component to achieve the best average performance.. exhaust back pressure is another example of PD effecting engine performance..

Mistake to blast holes in air box, imho
the following link will explain in much more depth than I care to.......
Your Airbox, Friend or Foe? | Thunder Products

Most often re-jetting is required after such modifications, especially on larger engines.

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post #9 of 12 Old 01-28-2017, 05:15 PM
 
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Needed a little more air due to re-routing some wiring into the airbox from the snorkel and restricted the flow a bit. It's a $1500 motorcycle bobber. Not going to get too concerned about a little extra air. Still running the stock filter and the plug check still has good color. The beauty of the UNI vents are that you can tape them off from the inside with gorilla tape if you find that you are getting too much air.
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post #10 of 12 Old 01-28-2017, 06:26 PM
 
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Quote:
Originally Posted by SoakedKarma View Post
The air box is engineered to restrict the inflow slightly so that the box internal pressure is lower than outside atmospheric pressure and air flow velocity faster..

"Pressure Differential" and the fluid Velocity it creates is engineered into each engine component to achieve the best average performance.. exhaust back pressure is another example of PD effecting engine performance..

Mistake to blast holes in air box, imho
the following link will explain in much more depth than I care to.......
Your Airbox, Friend or Foe? | Thunder Products

Most often re-jetting is required after such modifications, especially on larger engines.
I agree.. Air induction is a lot more complex than it seems to be at first glance. Why the filters on these Holes? if you perforate the airbox, the stock filter is still in place doing its job inside.

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