The bike has undergone a good deal of disassembly…actually all bolt on parts have been removed and the frame is naked. Ready for paint. I am left with only pieces of motorcycle, all neatly sorted into boxes and some things have actually been bagged and labeled. It has gotten to cold to work comfortably in the outside shop so much of the project has been brought into the basement workspace for detailed work, painting and some assembly. Modifications to the frame have primarily focused on the subframe where unneeded attachment points have been removed and new mounting points have been welded in place for the saddle bag racks. The inner fender had been cut and modified to accept the new narrower Acerbis rear fender. A bar was welded across the lower rear of the subframe to attach the rear fender.
The main frame has had the stock skid plate mounts removed as I will be installing the old plate from my ’09. The upper subframe mount has been drilled through to install the upgraded single bolt. Since the stock fairing and light assembly will not be used I have fabricated a new mounting bracket to hold the dual H4 light assembly as well as the modified fairing. In addition to the subframe bolt drilling I have drilled and tapped the foot peg mounting holes to accept 10mm bolts. The seat was cut down about 7 inches. I had the seat recovered in black vinyl. I am hoping that moving the luggage load forward 7 inches will help the handling. The rear of the subframe looks like it will make an excellent handle when wrestling the bike though deep mud or sand if I get stuck.
My welding skills are rudimentary at best. My equipment is bare bones wire feed no gas MIG. Of course I started the welding parts of this project on the most difficult item, the rear saddle bag rack. I used 1/2 square stock for the mounting supports , 5/16 round for the bag supports, and 1/8 round for the attachment loops. It does not look pretty but it seems strong and fits my Wolfman waterproof bags perfectly. I modified the mounting points on my Packrat luggage rack so I have the option of carrying my aluminum panniers for extended mostly on road trips.