Down under, an idiot and a 400F

I'm thinking of bending up an Alu seat pad up soon for my bike. I have some ideas on how I will attach it too but was hoping for some guidance up front, as I want the fit to be seamless once the padding and leather/vinyl goes on.

As a reminder here is my seat:



I am going for this type of look with the final seat:



I want to make sure the final seat matches the profile of the metal part perfectly vs following its own form which I see quite a bit.

So questions:

1. I'm going to use the flat/curves part of the seat hump to form my Alu pad. It will match the profile as perfectly as possible. However how much smaller should I make the pad to ensure it fits perfectly all around the edges?
2. I'll be using Velcro or 3M's equivalent to attach the pad to the pan, however I want the locating of the pad to be precise. Thinking of a couple of locating pins or a locating wide tab up the front, anyone got some ideas on how to execute this? Don't want a solution that will scratch paint afterwards so maybe some pins with rubber grommets to house them in the seat pan?
 
Why are you putting reg/rect inside a sealed box?
It isn't good for it not to have any airflow. Not sure if the seat base will conduct heat fast enough to be used as a sink?
Oem base gasket and a solid copper (or laminated stainless) head gasket. OEM head gasket won't work with oversize pistons
 
crazypj said:
Why are you putting reg/rect inside a sealed box?
It isn't good for it not to have any airflow. Not sure if the seat base will conduct heat fast enough to be used as a sink?
Click to expand...

The open side of the box will be open to the air PJ. It will be open underneath the subframe tray, above the shock.

I made a box because I didn't want it stuck directly to the tray looking like an afterthought. So the box is there to recess it.
 
It should be fine, I just like copper gaskets because I take things apart to 'check' it out' after a real good thrashing (13,500rpm+ ;) )
 
I should think so but, you know I'm a bit paranoid about keeping them cool. (from the years of repairing busted Suzuki and Kawasaki ones ::) )
Maybe a few louvers on the sides? (you'll probably need custom car crew for that? ;D 8) )
 
Original plan was to mount to the battery box but the lack of air moving past had me worried. So changed it up and had it in open air but recessed into the subframe tray so that once it's all painted black it won't be noticeable.

I was assuming having it above carbs and slight rearward would offer plenty of air flowing past to cool the rec reg. Plus attaching to subframe tray and some solid mounts might help to sink some of the heat away too.
 
LOL, for some reason I missed the bit where you said your cutting out a section to make a recessed box :-[
 
The wife is being very kind at the moment and allowing me a couple of hours here and there to work on the bike.

I've been waiting to get the bike back before finishing off the subframe tray, but today impatience got the better of me and so I cracked out the welder, angle grinder, files and grabbed a load of old photos, to try and get the tray finished off.

First up I drilled the box for the rec/reg mounting holes, then cut out 1 side of the box to allow for the rec/reg connector block to slide through:



I need to grab some new mounting hardware, but it will do for the moment.

I did a fair bit with the hand files to try and keep some accuracy to the lines:





Here you can see the planned amount the rec/reg will protrude below the tray:



Next I cut the hole. Again I finished it off with a hand file to try and keep the gaps as minimal as possible as I didn't want to add too much weld as I was worried it would warp the tray something terrible:



Test fit with some magnets keeping it in place:



All welded up and the hole cut for the RFID receiver:



Top view:



Liking how discrete the items are from the side. It's a hint that something functional is there but not in plain sight:



I was pretty careful welding the box in and whilst I was able to control warping well, the edges were not as sharp as I would like, even after some file and dremel action. But it will have to do and hopefully blends a bit more when it's painted or powder coated:

 
neevo said:
The wife is being very kind at the moment and allowing me a couple of hours here and there to work on the bike.
Click to expand...

Be careful mate... Sounds like a trap


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dannywrx88 said:
Be careful mate... Sounds like a trap
Click to expand...

Hahahahaha. No trap, she's a good egg. Looks after our kids like a champ, doesn't roll her eyes too much when I ask to work on the bike or go ride dirt.

I'm pretty lucky. 6 years married coming up on Friday too.
 
neevo said:
Hahahahaha. No trap, she's a good egg. Looks after our kids like a champ, doesn't roll her eyes too much when I ask to work on the bike or go ride dirt.

I'm pretty lucky. 6 years married coming up on Friday too.
Click to expand...

No wonder you married her lol.. Happy anniversary for fridau


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