Prowler

[LIAW]

to make my radiator I bought some new mesh and used an old piece of stainless sheet from my 'store' area, this has been an interesting challenge,

I measured the size I need for the whole front area and marked it on the sheet of stainless,

to bend over the sides as it is would require quite a big sheet folding tool which I don't have, so to make the bending easier I used a thin cutting disc in a grinder to cut half way through the marked out lines (like scoring cardboard), after removing excess material at the corners I was able to bend the sides to the required angles,

I welded up the corners to keep the shape and measured and drilled holes in the sides for the mounting bolts,

I cut away the corner where the radiator cap goes and offered it up for fitting,,

I marked the side design I wanted and cut away the areas I didn't want, then welded in an extra piece of stainless in the gap caused by cutting away for the radiator cap,

I then measured the size of the area needed for the mesh and cut that away, then all the corners and cut edges were smoothed and straightened to tidy it all up,

to get the front lower mounting holes marked I ground a couple of bolts into spikes and screwed them into the radiator thread holes, with some tape on the inner sides of the cover and the radiator area spaced out correctly with tape etc., I fitted the cover back on and pressed the areas where the spikes were, when the cover was removed I had the exact location marked into the tape where the holes needed to be drilled,

once it all fitted correctly I cut the mesh to the required size and spot welded it in place on the inside, I also welded some washers over the lower mounting holes to give the correct spacing and keep the mesh slightly proud of the radiator surface,

when I was happy with this I spent 4 hours polishing it all up and now it is fitted back onto the bike,

 

(this job was a lot more involved and complicated than what I've written here, I have simplified it as my finger would be worn out typing it all, more and better pictures with better explanations are on my face book page if you wish to see the whole process)

 

 

starting materials, after bending sides

[attachment=o15808]

 

radiator cap area welded in, all welds ground down and centre area removed

[attachment=o15809]

 

mesh welded in, all polished and fitted back on bike

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