Kawasaki Vulcan 800 Bobber Construct – Closing Touches & Check Experience

At present’s challenge focuses on making vital modifications to a Vulcan construct. Early within the course of, the workforce discovered a difficulty with the fuel tank that didn’t permit for correct coolant line clearance. To repair this, they selected to make use of a completely different tank that can match higher and permit the strains to run easily.

After updating the tank plan, the workforce labored on mounting the seat and fender. They created sturdy brackets to verify the seat and fender keep safe with out utilizing additional struts. The following steps embody placing again the facet covers and planning the exhaust pipes round these components.

Key Takeaways

• The present fuel tank wanted to be switched on account of clearance points.
• Seat and fender mounting options had been personalized for stability and elegance.
• Closing steps will embody becoming facet covers and planning the exhaust.

Vulcan Gasoline Tank Mounting Problem

Evaluating Excessive Mount and Center Mount Kinds

There are two principal kinds 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 challenge was a excessive mount mannequin.

Points with Coolant Line Clearance

With the excessive mount tankthe mounting tab will get in the best way of the coolant strains working beneath the body. The clearance isn’t sufficient, making it arduous to route the strains with out awkward changes.

A potential repair, like welding a bung, was thought-about however didn’t look or match proper for this challenge.

Steps for Changing the Gasoline Tank

As an alternative of forcing an answer, the present excessive mount tank will probably be saved for a special construct. The plan is to purchase a middle mount tank in order that the coolant strains can correctly match beneath.

Subsequent Steps:

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

This method ought to hold every part neat and make future upkeep simpler.

Seat Mounting Options

Utilizing Pre-Drilled Holes for Seat Attachment

He began by utilizing an present gap within the body to safe the entrance bracket of the seat. This methodology helped anchor the seat with no need to drill new holes. By making use of what was already there, he saved time and saved the mounting course of easy.

Including a Welded Cross Bar for Help

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

Seat Help Overview:

Further Bracket to Stop Seat Shifting

To cease the seat from transferring 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 spotpositioned to maintain issues as regular as potential. 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 might be certain the fender doesn’t shift or shake whereas using. Utilizing two factors helps hold every part agency.

A fast checklist of the steps for the preliminary mounting:

• Choose the primary spot for the fender.
• Bolt the fender down.
• Verify 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 connected. The bracket, constituted of scrap materials, wanted to be drilled for a bolt. After shaping and drilling, the bracket linked the fender to the body. Utilizing these two spots gave the fender sturdy help with out additional struts.

Supplies Used

By taking these steps, the fender stayed agency and matched the easy look. No additional help rods had been wanted. Every thing lined up and saved the fender from transferring round.

Facet Covers and Pipe Adjustment

Placing the Facet Panels Again On

The following step is to reattach the facet panels earlier than engaged on the pipes. That is vital as a result of it helps verify if the pipes will stumble upon the covers later. The facet covers must be in place so you may form and place the exhaust accurately.

Steps:

• Line up the facet covers with their mounts.
• Fasten them securely.
• Verify that every part 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 pipethe plan is to have it exit and run beneath the plastic on the again. The plastic piece in the best way will must 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 components.
• The plastic blocking the pipe must be lower.
• 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 strains. A brand new tank with a center mount will probably be ordered, so the coolant strains match beneath. The unique tank will probably be saved for an additional challenge.

Seat Progress:

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

Rear Fender Work:

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

Facet Covers and Pipes:

• Facet covers will probably be reinstalled to verify pipe clearance.
• The rear pipe will probably be rerouted beneath 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.