Blue peter Moment - here's one I made earlier
 

Thought I’d share my little fettling session with everyone.
My latest ride, XT660R, came with a manufacturers sump guard, but I felt it failed to protect certain parts of the engine . . . so I thought I’d knock one up myself . . . . .

Start with some cardboard and the original sump guard . . .



http://imageshack.us/a/img9/9805/sumpguard1.jpg
Trim the cardboard to a shape / size by mounting it onto the bike using the original fittings and you get this . . .



http://imageshack.us/a/img197/4760/sumpguard2.jpg


Bend and tape the trimmed cardboard template on the bike and you get this . .

http://imageshack.us/a/img33/1328/sumpguard3.jpg

http://imageshack.us/a/img547/7124/sumpguard4.jpg

Mark up your alloy plate using the trimmed template . . .

http://imageshack.us/a/img268/7967/sumpguard5.jpg

Cut out the template shaped alloy and start drilling holes and creating some depressions for the mounting bolts to sit in, using my favourite tools . .

http://imageshack.us/a/img839/7968/sumpguard6.jpg


The start doing your Uri Gellar thing and get bending, using the original guard as a guide . . .

http://imageshack.us/a/img706/1116/sumpguard7.jpg

Then, with a few bends in place, test fit to make sure the holes you’ve drilled line up . . .

http://imageshack.us/a/img811/7715/sumpguard8.jpg

http://imageshack.us/a/img850/2062/sumpguard9.jpg

Once you’ve got the mounting points sorted, you bend the edges of the guard to make them more conformal to the engine . . . and “Voila" you got one home made sump guard. . . . .

http://imageshack.us/a/img832/5017/sumpguard10.jpg

http://imageshack.us/a/img14/2505/sumpguard11.jpg

http://imageshack.us/a/img705/5089/sumpguard12.jpg

Still got some finishing to do, but in the main that’s it, job done.
Here we see the cardboard template and the nearly finished alloy item side by side . .

http://imageshack.us/a/img689/5069/sumpguard13.jpg


Steve T


:cool:

Hey, nice job! Get it painted and post the finished result :)

Nice job and great pictures thanks!! Just one thought from a non technical fellow, will this large guard not prevent some air flow around the engine and therefore keep the engine warmer??? Over to some experts please......

I dont think cardboard is strong enough - even if you paint it.

Job done, methinks . . .

http://imageshack.us/a/img195/5673/sumpguard14.jpg

http://imageshack.us/a/img11/8486/sumpguard15.jpg

http://imageshack.us/a/img42/8240/sumpguard16.jpg

http://imageshack.us/a/img248/9276/sumpguard17.jpg

Couple of air holes in situ, and if not sufficient, more can be added

Steve T

:cool:

Bravo! Looks ace!

:clap: