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 . . .




Trim the cardboard to a shape / size by mounting it onto the bike using the original fittings and you get this . . .






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





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



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 . .




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



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





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. . . . .







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 . .




Steve T

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A weekend wasted isn't a wasted weekend

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......

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(Now sold on, sob) 2011 Blue XT660X with gold wheels, was 26,500 km.
Engine mods: K&N Stage 1 filter, DNA Stage 2 filter, snorkel removed, Kev fuel mod fitted.
Plus: smoked Puig screen, Yam aluminium sump guard, Yamaha / Acerbis handguards, Givi Trekker aluminium side cases, Leo Vince X3 cans plus Kev front fork mod and Fender Xtender. Just fitted Michelin Road Pilot 3 tyres.

SOLD the XTX for a Super Ten 1200. And just bought a Raptor 700 so staying on here for some tips....

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

Job done, methinks . . .









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

Steve T

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A weekend wasted isn't a wasted weekend

Bravo! Looks ace!