Airtech fairings - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
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post #1 of 30 (permalink) Old 11-15-2019, 2:27 PM Thread Starter
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Airtech fairings

I was just wondering who out there has used them ,and if u have any tips,tricks,or fitment help to share. Im installing a front cowling and full lower fairing. Upper fairing and front fender were damaged in a deer accident, and I liked the look of the lower. I figured since I have to paint parts that I would change the color of the bike. I will post some pics of the fairings and the project . Brian
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post #2 of 30 (permalink) Old 11-15-2019, 2:33 PM Thread Starter
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Just figured out how to post pics lol
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post #3 of 30 (permalink) Old 11-16-2019, 5:40 PM
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Fit everything first. Drill out the required holes and make sure you leave a clean edge. Gel coat shatters fairly easily.



Wet sand and let dry before priming. Don't rely on the primer that comes on the parts. That will give you plenty of time to look over every inch for pin holes. Fill your pin holes before priming.



Once you have the holes drilled, and everything primed make sure to tack rag your parts before spraying. About it really. Air Tech stuff is good quality and doesn't require all that much prep.....sean


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post #4 of 30 (permalink) Old 11-16-2019, 7:29 PM
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I always liked the looks of that Airtech full lower fairing as well. One trick I learned while fitting fiberglass parts on cars was that, if necessary, you can use a hot air gun to carefully "adjust' the shape a bit to get the fit of the parts as perfect as possible. Even quality stuff like Airtech warps a little when it comes out of the mold. Be as fussy and as patient as you can be at the fitting stage because any imperfections will stand out more after the final color is applied.

I'll be interested to see how your project progresses.
post #5 of 30 (permalink) Old 11-16-2019, 10:23 PM Thread Starter
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Got a little bit done today on the upper fairing. Windscreen and headlight mounts pretty much done. The pointy windscreen studs were the PO's donation lol. Headlight mounts were cannibalized from factory fairing and are epoxied in now I'm gonna glass them in before final fitment. Definitely easier than fabing my own . Paint will be done by my stepfather he's a retired paint and body man . I'll be using matrix 2k urethane primer and clear. The paint is deltron 500 sun fire rust with copper flake . I happened into the paint for free at 144$ a quart I was happy lol.
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post #6 of 30 (permalink) Old 11-16-2019, 10:38 PM Thread Starter
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Pics didn't want to load.
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post #7 of 30 (permalink) Old 11-17-2019, 9:50 AM
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That sounds like a cool color. I'm interested to see the final product.
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post #8 of 30 (permalink) Old 11-17-2019, 9:21 PM
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I need a new front fairing and love that full lower one too! Will be interested to see more of your work, the windscreen looks great. Unsure of my skills so been holding off on the purchase.

I'm a Ninja........................'09 Ninja 500R
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post #9 of 30 (permalink) Old 11-19-2019, 4:49 PM Thread Starter
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I need a new front fairing and love that full lower one too! Will be interested to see more of your work, the windscreen looks great. Unsure of my skills so been holding off on the purchase.

The front fairing is fairly easy. Only real problem I had with it was getting the reveal to match stock. It was a pretty simple fix light sanding test and repeat lol. Then repeat some more . Mirror mounts are not drilled but easily seen through the gel coat. That's the first holes I drilled . Bottom fairing stay holes were next and u can mark them from the inside . I decided to drill them a touch bigger than stock as it allowed to tweak the bottom around a bit. One thing to be considered is the airtech fairings are considerably thinner . As the lower bolts ride on a grommet there is slop in the connection . I'm probably gonna remedy mine with some rubber washers to allow movement . I am by no means a body man lol I'm a electrician by trade 27 years so I'm familiar with most tools . My stepfather is a retired body and paint guy so I got allot of experience in that as well . I think if u have a general knowledge of the tools required ud be all right . The good thing is its glass so if u F up a bit u can fix it for 20 buck price of some glass and resin . I'll post again about the lower fairing that's what I'm on now . Hope this helps someone else like me who was looking for info. PM me if u got questions I would be glad to help where I can .
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post #10 of 30 (permalink) Old 11-19-2019, 4:50 PM Thread Starter
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Sorry when I mentioned the reveal I was talking about the headlight. The rest is pretty much predetermined
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post #11 of 30 (permalink) Old 11-19-2019, 6:00 PM
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Fiberglass and gelcoat, both being more rigid than the OEM ABS fairings, I would place a thin piece or rubber between the fairing and hard (metal) mounts if possible, as a cushion and slight vibe absorber. You can cut pieces from an old inner tube, even a bicycle tube will do.

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post #12 of 30 (permalink) Old 11-19-2019, 6:23 PM Thread Starter
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Quote:
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Fiberglass and gelcoat, both being more rigid than the OEM ABS fairings, I would place a thin piece or rubber between the fairing and hard (metal) mounts if possible, as a cushion and slight vibe absorber. You can cut pieces from an old inner tube, even a bicycle tube will do.
Spot on there . I think even going a bit thicker isn't out of he question. With the difference in thickness between OEM and glass some hardware store rubber washers will work great. Probably won't have more than a couple bucks spent in total. When u consider the 2 fairings with shipping were half a grand it's a drop in the bucket. Brian
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post #13 of 30 (permalink) Old 11-19-2019, 8:13 PM
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If the Airtech parts are that much thinner, you could maybe build up the thickness and reinforce a bit with a patch of cloth and resin at each fastener location? Using rubber washers is for sure a good idea but you will need to locktite the bolts because you won't be able to torque them like with the stock ABS parts. Have you considered using Dzus fasteners for the bottom fairing? That would add time and $$ to the project but would sure be handy for getting the bottom half off in a hurry.

You're lucky to have an experienced paint guy in your corner. That's the trickiest part of the whole job.
post #14 of 30 (permalink) Old 11-19-2019, 9:04 PM Thread Starter
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I like it the look of those fasteners . Definitely would take a little cutting and welding ,but not out of the realm of possibility. I was trying to think of a way to turn the factory mounting point into some sort of nylock fastener. So fairing bolts could stay seated without being bottomed out ,but not have to be recoated everytime they are removed. I see ur point with the rubber washer letting the bolt possibly back out due to vibe. Having a pro painting is definitely a plus ,but my prep work gets picked apart lol.
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post #15 of 30 (permalink) Old 11-20-2019, 9:12 PM Thread Starter
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Small update little off topic but part of the build . The DIY fender eliminator with new koso unlimited led blinkers . They are about a 10th the size as stock but just as visible in day time ,and I would say considerably more viable at night .
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post #16 of 30 (permalink) Old 11-27-2019, 8:18 PM Thread Starter
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Sorry about the delay we've had some nice weather here so have been hard at it. The full lower fairing left a little bit to be desired. Radiator mounts are in stone being recessed in the fairing. Which left the belly pan bolts about a 3/8 of an inch from the end of the fairing. . I glassed about an additional 3/4 to the end of the fairing. Also laid 5 more layers of glass to the nose which was maybe 3/16ths thick . Not huge problems but the lower was definitely not bolt on and ride. Also finished glassing in the head light mounts .I will post some pics of glass work tomorrow, but here's a little eye candy for now . What ya think.
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post #17 of 30 (permalink) Old 11-28-2019, 9:13 AM
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Nice color!
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post #18 of 30 (permalink) Old 11-28-2019, 12:32 PM Thread Starter
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Nice color!
Thnxs you gotta nice looking color as well
. Do u happen to know the color of ur bike? Mine is sun fire rust its actually a factory color for a 06 Nissan murano. Paint shop was trying to match a Kia color and it wasnt even close . Color gun gave this paint code lol. Ended up with a free quart.
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post #19 of 30 (permalink) Old 11-29-2019, 8:49 AM
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Thnxs you gotta nice looking color as well
. Do u happen to know the color of ur bike? Mine is sun fire rust its actually a factory color for a 06 Nissan murano. Paint shop was trying to match a Kia color and it wasnt even close . Color gun gave this paint code lol. Ended up with a free quart.
It is supposed to be a Burnt Orange metallic color, like that of the Chevy HHR, but I don't know the year. It was applied on a white primer, with 4 layers of paint. In the first two layers the color was very clear, beginning to darken in the third layer. With the fourth layer of paint it was to my liking.

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post #20 of 30 (permalink) Old 11-30-2019, 6:27 PM
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Ive used them om my race bike 94 EX500 upper lower With oil catch and the one piece side and tail section Fitment is very good Just takes a month of Sundays for the order to ship Good quality Good stuff
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post #21 of 30 (permalink) Old 12-5-2019, 9:06 PM Thread Starter
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Sorry this took a couple days trying to push my rehab a little and get back to work . Canabilized headlight mounts ,extended lower, and thickened belly . I know my extensions on the lower could have been finished a little cleaner, but who's gonna see it lol.
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post #22 of 30 (permalink) Old 12-6-2019, 9:40 AM
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Looking awesome! I had an 03 SV650 in the burnt copper color, close to your color- it is beautiful, can't wait to see it all together, especially with the lower fairing. Really nice work on all the bodywork, headlight mounts and cleaning up the rear as well- are those Koso blinkers expensive? All relative i suppose when " 2 fairings with shipping were half a grand"- i'm still laughing at that one!
So much prep goes into a re-body like this, great attention to detail shown, thanks for posting, definitely an inspiration for us winter bound riders! On Long Island here, deer and snow are the worst

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post #23 of 30 (permalink) Old 12-6-2019, 8:20 PM Thread Starter
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The kosos for the rear were 75 buck and fit in one of the oem rubber grommet holes perfect. I pick the koso mars led for the front . I didn't have them at the time so I just frilled the hole 10mm their spec says 8mm . I like the idea of rubber washers both sides can't afford a cracked upper at thi point lol. I know a lot of guys would laugh at the money spent on this bike . I like the soort tour type of ride I've had lots of bikes . 10 years ago I built the pic and hardly get to ride it honestly I have more fun on the ex.
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post #24 of 30 (permalink) Old 12-6-2019, 8:53 PM Thread Starter
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Looking awesome! I had an 03 SV650 in the burnt copper color, close to your color- it is beautiful, can't wait to see it all together, especially with the lower fairing. Really nice work on all the bodywork, headlight mounts and cleaning up the rear as well- are those Koso blinkers expensive? All relative i suppose when " 2 fairings with shipping were half a grand"- i'm still laughing at that one!
So much prep goes into a re-body like this, great attention to detail shown, thanks for posting, definitely an inspiration for us winter bound riders! On Long Island here, deer and snow are the worst
I try not to laugh about it lol it hurts . But we all spend are money on something kids are gone house is paid why not ? I'm to old for a liter bike lol
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post #25 of 30 (permalink) Old 12-6-2019, 9:08 PM
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I hear ya, i picked up my EX crashed for 300- probably have 3 times that much into it, but can't think of another bike for 1200 i would enjoy so much, both riding and modding. My VFR is way faster and sounds so much better, but i'm at 75-80 mph before i start to feel the speed on it... the EX i'm feeling like Rossi at 35-40

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