my diy form for a fiberglass cafe seat/cowl
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Thread: my diy form for a fiberglass cafe seat/cowl

  1. #1
    Member agreeablesteve's Avatar
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    my diy form for a fiberglass cafe seat/cowl

    Made a form and pulled the seat out of it last weekend. I plan to put the battery in the rear bump. From time to time over the last couple years I viewed Larry's seat thread to glean some knowledge and wisdom. Figured I would give it a go. I don't have the skills the man has, but I'm not afraid to learn and make some mistakes. The original plug for the female form was my existing cowl (cut and welded an old cb360 tank). I have a ways to go for this fiberglass seat. Took about 3 months of puttering around with just the form. Not on a timeline but will post a picture of the finished seat when I get there.

    Again much thanks to the folks on this forum for sharing their wisdom to indirectly help me out. I do love using google search with "cx500forum" and whatever info I am looking for at the time: e.g. "shep method" "stator test" "7 volt regulator" "rear sets" "overheating" "tachometer seal"... "oil"

    Hope the link works...

    Last edited by ramprat06; 04-24-2017 at 01:15 PM.
    Steve

    1981 Honda CX500 Deluxe

    Duluth, MN

    http://s1275.photobucket.com/user/ag...steve/profile/

  2. #2
    Senior Member Brian Sams's Avatar
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    Link doesn't work for me. FYI.
    78 CX500 Cafe Project 99% Complete
    82 CX500 Custom
    83 GL650 Zissou Tribute Bike
    83 GL650 Interstate (AKA Donorcycle)
    78/83 CX500/650 Cafe Super Standard 99% Complete!

  3. #3
    Member agreeablesteve's Avatar
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    Thanks Brian for the FYI. Fish Trap Lake, wonder if you know any Nielsens or Longtines over that way? Here are a couple of images from this project. I'll be cutting, shaping, sanding and filling the seat over the next few weeks. Will throw up an image when it's dialed, wired and done. The link in my signature has a few photos of the seat and the bike over time... not quite a build thread... mostly a mock up thread. Ride safely.
    Name:  1 cafe cowl.jpg
Views: 393
Size:  1.00 MBName:  cafe cowl 2.jpg
Views: 392
Size:  1.51 MBName:  cafe cowl 4.jpg
Views: 385
Size:  1.97 MBName:  cafe cowl 5.jpg
Views: 407
Size:  2.55 MB
    OCR, Brian Sams and CXPHREAK like this.
    Steve

    1981 Honda CX500 Deluxe

    Duluth, MN

    http://s1275.photobucket.com/user/ag...steve/profile/

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  5. #4
    Senior Member Brian Sams's Avatar
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    No Nielsons or Longtines, at least not more than seeing the names around. Your project looks good, I'll be keeping an eye on it!
    78 CX500 Cafe Project 99% Complete
    82 CX500 Custom
    83 GL650 Zissou Tribute Bike
    83 GL650 Interstate (AKA Donorcycle)
    78/83 CX500/650 Cafe Super Standard 99% Complete!

  6. #5
    Member agreeablesteve's Avatar
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    Name:  draft of the lights on the cowl.JPG
Views: 291
Size:  108.3 KBName:  tail and break lights go in here.jpg
Views: 293
Size:  415.8 KBName:  the new fiberglass cowl and the old one made with a gas tank.JPG
Views: 330
Size:  923.7 KBName:  blinkers on the cowl.jpg
Views: 285
Size:  487.3 KBName:  wires to fit under the seat of the cowl using trailor connectors.JPG
Views: 305
Size:  1.41 MBName:  spray painted with rustoleum last night in a tent 2 coats one hour apart.JPG
Views: 280
Size:  408.2 KBName:  cowl from the rear and side quickly set on this morning before work.JPG
Views: 294
Size:  582.3 KBName:  quick set on the bike this morning before work to mock it up.JPG
Views: 282
Size:  300.8 KB Little more progress... After a bit of sanding, adding fiberglass, applying some filler and a couple coats of primer, I decided to use a rattle can of Rustoleum Sunrise Red to mock things up. I previously roller brushed the tank a couple years back. Sprayed the can in a small tent last night and the results were surprisingly nice. Two coats about an hour apart. As I probably only have about 8 more weeks to ride up here before the snow, I'll connect it all together after work tonite so I can ride the rough draft tomorrow to my usual weekend breakfast spot. The plan is over the next few weeks to fiddle with it, shape it, get the lines dialed and then over the winter have it professionally upholstered. Been a great project. Again appreciate the wisdom that can be found here. For me all the gear all the time...got a great deal on a Aerostich Darien Jacket with all the armor, love it. Ride safe.
    OCR, LuciferJesus and CXPHREAK like this.
    Steve

    1981 Honda CX500 Deluxe

    Duluth, MN

    http://s1275.photobucket.com/user/ag...steve/profile/

  7. #6
    Senior Member MobileAZN's Avatar
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    While it is nice that you can reuse the form, for my one-off cowl, I used floral foam, made the shape I needed, taped, waxed, then glassed it. When it was cured, I pulled the foam out and sanded (paddlewheeled) until smooth. Came out great and took less than a weekend. I can throw up pics if anyone wants to see that process.
    LuciferJesus likes this.
    1980 Honda CX500 Custom (In a pile of parts, current project)
    1981 Suzuki GN400CR (Cafe Racer, current ride)
    1976 Honda CB125S1 (Full original restoration. Sold her and miss it. Every. Single. Day.)

  8. #7
    Member agreeablesteve's Avatar
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    Name:  image.jpeg
Views: 256
Size:  807.7 KBSo this where it ends up for the rest of my season. Put on a hundred miles on the seat with only a cut out rubber anti fatigue floor mat for a cushion. Name:  image.jpeg
Views: 233
Size:  258.3 KB Good enough for now and will shape up over time. Ride safe.
    JiMi and OCR like this.
    Steve

    1981 Honda CX500 Deluxe

    Duluth, MN

    http://s1275.photobucket.com/user/ag...steve/profile/

  9. #8
    Member agreeablesteve's Avatar
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    MobileAZN: Garden foam works great for sculpting. I used it a few years back to make a form to add a fiberglass plug for the dip in the cx frame. Throw a pic up of yours if you'd like. Works great for one-offs and a person could make a form out of that if they wanted to make more than one. Couple photos of the garden foam below. First was the result, second the mock up.
    Name:  gardenfoamformunderneath_zpsa7f9e663.jpg
Views: 203
Size:  130.1 KB
    Name:  621538_3960443044067_1598276127_o.jpg
Views: 217
Size:  112.5 KB
    Steve

    1981 Honda CX500 Deluxe

    Duluth, MN

    http://s1275.photobucket.com/user/ag...steve/profile/

  10. #9
    Member agreeablesteve's Avatar
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    Name:  cowl.jpg
Views: 116
Size:  186.0 KBThis where I ended up with the seat/cowl over the winter... between skiing. Bought a seat cover off ebay for about 25 bucks. Think it was for a cb bike. Cut and covered it. I've ordered a couple of red Honda badges for the spots on both sides where the vinyl didn't match. Attached a picture with the snaps I put on and drilled in. Name:  IMG_3230.JPG
Views: 110
Size:  1.04 MB Overall, very pleased. Upgraded to a mosfet rectifier and relocated it. Have some comstar wheels 18 and 19 that I will put on instead of the reverse comstars at some point. Thinking Hagon shocks and will rework the exhaust will happen over the summer (rainy day project). Like the harley dyna mufflers I have on it and the sound, but want some reverse cones. That too will be on the agenda.

    Thanks again for all the wisdom that can be found on the site. Ride safe.
    Steve

    1981 Honda CX500 Deluxe

    Duluth, MN

    http://s1275.photobucket.com/user/ag...steve/profile/

  11. #10
    Senior Member MobileAZN's Avatar
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    Looks good! I must have missed the post from 2016. That's the same stuff I used for making mine.
    agreeablesteve likes this.
    1980 Honda CX500 Custom (In a pile of parts, current project)
    1981 Suzuki GN400CR (Cafe Racer, current ride)
    1976 Honda CB125S1 (Full original restoration. Sold her and miss it. Every. Single. Day.)

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