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Old 03-23-2011, 07:53 PM   #13
jesusgatos OP
fishing with dynamite
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Joined: Nov 2006
Location: on the road
Oddometer: 2,393
The big idea with these handguards was to make a 'basket' on the bottom that should keep hands/wrists from getting tangled-up in the handguards in a crash. So I wanted to wrap them under the bars and back as far as possible, but without interfering with anything. Spent a few hours today hollowing-out the new handguards to check the fit. Took these pics of myself sitting/standing on the bike as far forward as I could possibly get. Clearance was good everywhere, and I figured out that I could extend the bottom back even a little bit further (on the inside) without causing any problems.

Taped-up another paper basket and poured some more foam. Unlike the fiberglass resin, this stuff bonds to itself really well. Filled the whole thing up since I was finished checking the fit and the hollowed-out foam was really flimsy.

Raised the front/top edge a little bit and then slathered-on a layer of bondo. Going to do a little bit more shaping and styling tomorrow.

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