Kawasaki Vulcan 800 Bobber Construct – Last Touches & Check Trip

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

After updating the tank plan, the staff 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 embrace placing again the aspect covers and planning the exhaust pipes round these elements.

Key Takeaways

• The present fuel tank wanted to be switched on account of clearance points.
• Seat and fender mounting options had been custom-made for stability and magnificence.
• Last steps will embrace becoming aspect covers and planning the exhaust.

Vulcan Fuel Tank Mounting Problem

Evaluating Excessive Mount and Center Mount Types

There are two most important varieties 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 excessive mount tank, the mounting tab will get in the best way of the coolant strains operating below the body. The clearance just isn’t sufficient, making it arduous to route the strains with out awkward changes.

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

Steps for Changing the Gasoline Tank

As an alternative of forcing an answer, the present excessive mount tank can be saved for a distinct 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 area for coolant strains.

This strategy ought to preserve every part neat and make future upkeep simpler.

Seat Mounting Options

Utilizing Pre-Drilled Holes for Seat Attachment

He began by utilizing an current gap within the body to safe the entrance bracket of the seat. This technique helped anchor the seat without having 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 Assist

To carry the rider’s weight, a help 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 Assist Overview:

Additional Bracket to Stop Seat Shifting

To cease the seat from transferring aspect to aspect, 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 attainable. 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 may ensure that the fender doesn’t shift or shake whereas driving. Utilizing two factors helps preserve every part agency.

A fast checklist of the steps for the preliminary mounting:

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

Welding the Aspect Bung and Constructing the Second Bracket

For the second mounting level, a metallic bung was welded onto the aspect 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 related the fender to the body. Utilizing these two spots gave the fender robust 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. All the things lined up and saved the fender from transferring round.

Aspect Covers and Pipe Adjustment

Placing the Aspect Panels Again On

The following step is to reattach the aspect 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 aspect covers should be in place so you may form and place the exhaust appropriately.

Steps:

• Line up the aspect covers with their mounts.
• Fasten them securely.
• Examine 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 pipe, the plan is to have it exit and run below the plastic on the again. The plastic piece in the best way will should be trimmed off. This offers sufficient room for the brand new pipe and avoids contact with the aspect 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 strains. A brand new tank with a center mount can be ordered, so the coolant strains match beneath. The unique tank can be saved for an additional venture.

Seat Progress:

• The entrance bracket for the seat makes use of an current gap for mounting.
• A help 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 help bar, so the seat stays regular.

Rear Fender Work:

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

Aspect Covers and Pipes:

• Aspect covers can be reinstalled to verify pipe clearance.
• The rear pipe can be rerouted below 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.