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Old 01-27-2013, 08:37 PM   #1
richarddacat OP
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Making a Smuggler?

I'm starting my first attempt at fiber-glassing by making a storage box out of the rear seat pan from a FJR. A homemade Corbin Smuggler so to speak.

My idea is not to make a mold but use layering on top of a cardboard fabricated structure. Beginning with a stock seat pan I'm building the box on top of the stock plastic pan.

This outside shell is built of cardboard will be covered with aluminum tape, a release product like paste wax will be smeared on it and then start applying the FG.
The completed shell will be smoothed out with Bondo and probably rattled canned. The lid of course will have a hinge and latch, details of this are or any of it are not drawn out, just a idea I've had in my head.

The shell is now built out of cardboard but I need to fab the attaching brackets so to speak to the base pan.
My idea on this is to build a second piece that's will be on top of the seat pan, doing this I can bolt the new FB to the pan then the new base can be attached to outer shell from the inside. Maybe at the same time the outer piece is being glassed, not sure yet how best to go about it.

I'm tossing ideas about supporting tabs, sheet metal bracketing (?) in four locations where holes can be drilled and bolts run through the seat pan and in the new seat pan base.

The lid will be a third piece.

I'd like to get any input to see if my idea will work or if anyones done a similar project. I've seen a aux. fuel tank built from the rear FJR seat pan, it looked little crude but effective.

I've done a little searching on here about some very creative projects from some very skilled bikers and saved a few links that are helpful. I'm not very skilled but particular and tend to get in a hurry so I'm vowing right now that this is something I don't need to rush.

Tips and suggestions are welcome.
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Old 01-28-2013, 02:06 PM   #2
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cool project, thake lots of pics. bete
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Old 01-28-2013, 03:27 PM   #3
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May try to start slapping fiberglas on it tomorrow. Need to find a good release agent, paste wax is what I thought I'd use.




Inside the box is another cardboard pan, I'll do the outside then fit the inside pan and attach.
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Old 01-28-2013, 05:18 PM   #4
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Quote:
Originally Posted by richarddacat View Post
May try to start slapping fiberglas on it tomorrow. Need to find a good release agent, paste wax is what I thought I'd use.




Inside the box is another cardboard pan, I'll do the outside then fit the inside pan and attach.
Awesome... I think I would have made it a little taller to incorporate a backrest. Nice going though and keep us posted...
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Old 01-29-2013, 05:56 AM   #5
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Liquid PVA works well as a release agent, as does liberal coats of clear Kiwi shoe polish.
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Old 01-29-2013, 06:08 AM   #6
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Liquid PVA works well as a release agent, as does liberal coats of clear Kiwi shoe polish.
How about Johnsons paste wax?
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Old 01-29-2013, 06:33 AM   #7
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Quote:
Originally Posted by richarddacat View Post

I don't think you can build a box that's any uglier than your seat. Did that saddle come off an AMF Harley?

I did something similar for my Tiger, but I built an aluminum 'lid' that takes the place of the whole passenger seat, and creates one larger storage area under the seat and where the seat would normally be. I fab'ed brackets so it still attaches and locks like a stock pass. saddle.
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Old 01-29-2013, 11:54 AM   #8
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Originally Posted by ABHulgan View Post
I did something similar for my Tiger, but I built an aluminum 'lid' that takes the place of the whole passenger seat, and creates one larger storage area under the seat and where the seat would normally be. I fab'ed brackets so it still attaches and locks like a stock pass. saddle.
I'd like to see of pic of that, if you don't mind.
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Old 01-29-2013, 01:54 PM   #9
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I'd like to see of pic of that, if you don't mind.
Same here, along with your seat.
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Old 01-29-2013, 05:35 PM   #10
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I was thinking the seat looked darn comfy. bete.
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Old 01-29-2013, 05:36 PM   #11
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saran wrap
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Old 01-29-2013, 05:46 PM   #12
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I was thinking the seat looked darn comfy. bete.
It's a Russell and it is darn comfy.

Thought about saran wrap but was afraid it would move on me too much, used paste wax and did some glassing today. Got a few bubbles and high spots, planning on smoothing them out and adding some more layers.
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Old 01-30-2013, 02:49 AM   #13
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Quote:
Originally Posted by richarddacat View Post
It's a Russell and it is darn comfy.

Thought about saran wrap but was afraid it would move on me too much, used paste wax and did some glassing today. Got a few bubbles and high spots, planning on smoothing them out and adding some more layers.
I don't know what paste wax is? sounds like something my wife would use
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Old 01-30-2013, 05:10 AM   #14
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I don't know what paste wax is? sounds like something my wife would use
From what I've read a wax without silicon works as a release agent. Johnsons paste wax is commonly used on wood floors.
If you can get your wife to wax anything, more power to ya.
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Old 01-30-2013, 07:25 AM   #15
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From what I've read a wax without silicon works as a release agent. Johnsons paste wax is commonly used on wood floors.
If you can get your wife to wax anything, more power to ya.
From bedding a few rifles I always found Kiwi clear polish to work well as a release agent and more importantly not be too thick as to affect the final product.
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