DIY no weld belly pan - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
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post #1 of 45 Old 02-25-2010, 02:47 PM Thread Starter
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DIY no weld belly pan

How about making a skid plate with no welding required
Mock it up in cardboard. When your satisfied with the clearances and shape, draw it out on the metal. I used aluminum Tread Plate because I like the embossed design. It's about a 1/16" thick so it bends easy. I will reinforce it with square 3/4" Al. tube or angle, as required. (make sure to allow for this in the clearances)
Make the cuts first, then drill the 1/2" holes where the bends will meet at ACA, ADA, BCB & BDB, then the side bends A & B, then the remaining bends, C, D & E.
Side veiw of the mock up. The bends are held in place by staples.
Bending the sides at A & B to 45 deg. or so. (yes that is just two pieces of hard wood flooring) You could probably bend up to 60 deg. if you wanted the sides a little steeper. (do it on the mock up to get everything right)
Persuading the bends to be a little sharper.
Checking the angle at 45.
9x12" blocks of wood used to bend C,D & E to 22.5 deg. The bend at E will depend on which crash bar you are using, and you may have to shorten or lengthen it to meet the bar as required.
It's taking shape now. Note how the side cuts overlap.
Note the rivets (3/16" x 3/8" long aluminum were used and the excess was just ground off on the inside) with backer washers. Three per joint equally spaced, sort of. Note how the edge becomes rounded when held together by the rivets. This tends to change the angles at C & D, so you must clamp the work to a table at the back and secure the angle at the front by placing something solid and cut to 45 deg. under D,E. Then C clamp the joints and drill and rivet.
Measurements: Back to C, 11.5". C to D & D to E, 5" each. E to the front is 2 1/4". Each side starts out at 5". A to B is 9". Most retail plate stock is 24", so that is what was used, and you can see that a 1/4 " is lost in the bends. I don't intend to use this plate to protect the engine while I'm humping it over boulders or curbs or the like, it's just for flying gravel, road debris and the like. If you have any questions feel free to post or PM. Bob...
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post #2 of 45 Old 02-25-2010, 03:27 PM
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Nicely done!!!!....

Post more pics as you finish it up and get it installed.

Ken

2007 DL650 Gray
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post #3 of 45 Old 02-25-2010, 03:52 PM
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Ah Crap,.............no welding? Come on, that's at least half of the fun!!!

[Nicely thought out and done. ]


B.
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post #4 of 45 Old 02-25-2010, 05:28 PM
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Sure looks nice. I'd just be a little worried about metal fatigue and breakage caused by the bending (ask me how I know), but that also depends on the Al alloy used.

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post #5 of 45 Old 02-25-2010, 06:40 PM Thread Starter
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Quote:
Originally Posted by Black Lab View Post
Ah Crap,.............no welding? Come on, that's at least half of the fun!!!

[Nicely thought out and done. ]


B.
It's only fun, if you own a welder! Yeh, I know, I just wanted to give the (weldingly challenged) some hope.

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post #6 of 45 Old 02-25-2010, 06:55 PM Thread Starter
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Quote:
Originally Posted by Arne View Post
Sure looks nice. I'd just be a little worried about metal fatigue and breakage caused by the bending (ask me how I know), but that also depends on the Al alloy used.
Got me thinking, so I bent a piece about 1" across back and forth greater than 90 deg. and it survived 7 times. The whole thing as a structure, with reinforcing, would of course, be much stronger, than a single 1" wide piece. Anyway it cost about $45.00 all told and would take about an hour to remake, so think of it as recyclable armour if you will. :mrgreen:

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The destination, can be the journey! Honest Bob

Last edited by honest bob; 03-08-2010 at 01:14 PM. Reason: changed text for better meening
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post #7 of 45 Old 02-25-2010, 06:58 PM Thread Starter
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Nicely done!!!!....

Post more pics as you finish it up and get it installed.

Ken
Will post more pics if the SW motech crash bars ever come in. Ordered Feb. 1st. Tried to support local dealer.

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post #8 of 45 Old 03-12-2010, 06:02 AM
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I pick up my Wee in a few weeks and have been surfing around looking for add-ons. This certainly gives me some inspiration, especially after seeing some of the prices being asked!

And I've a friend with a shop to boot.

Nice job.

Chich

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post #9 of 45 Old 03-12-2010, 08:12 AM Thread Starter
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I pick up my Wee in a few weeks and have been surfing around looking for add-ons. This certainly gives me some inspiration, especially after seeing some of the prices being asked!

And I've a friend with a shop to boot.

Nice job.

Chich
Thanks Chich; That's exactly why I designed it. Enjoy your new bike.

ADVENTURE, like beauty, is in the eye of the beholder.
The destination, can be the journey! Honest Bob

Last edited by honest bob; 03-13-2010 at 08:56 AM. Reason: Dang, sorry spelled chich's name wrong.
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post #10 of 45 Old 03-12-2010, 10:14 PM
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Very nicely done there... Are you taking orders yet?
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