Well, every bike needs a seat! This is how I make mine. I made a hinge seat that way I’ll have easy access to the oil tank at all times.
I bought the KZ650 years ago. I knew I would eventually have to fix or replace the engine cases, and of course the cracks were right on the threads which made the repair a little tricky. Well the time had finally come. I was in the middle of rebuilding the motor so I figured, why not now. I bolted the cases together, and removed the JB weld that was previously there. I then preheated the weld area with a propane torch. This was my first real test when it came to welding aluminum, so I was a bit nervous. The beads went in smooth with no real issues. I then ground down the welds and re-tapped the threads for the points cover bolts. I was more than pleased with the results!!
Well shit happens and bikes end up on their side. Luckily it was an easy fix, and you wouldn’t even know it was cracked.
So I wanted a fender that only mounted on one side of the fork. The original design I came up with seemed good enough, after all there’s not much of a fender. While off loading the bike one day I heard the fender make a “tin can” sound. Needless to say that drove me nuts. So back to the drawing board I went. I made the front of the mount more robust. I knew I also needed to stabilize the rear of the fender. I made a detachable strut that wraps around the fork and mounts to the rear of the fender. I decided to wrap the strut in fiber glass to save weight. The fender now has the rigidity it needs to keep things quiet.
This is a 05-06 Kawasaki 636 tank I had hanging around the shop. I bought the bike for parts. I used the majority of the parts on a KZ650 build. The 636 tank was not going to be used, so I figured mod it out and sell it.