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  Topic Review (Newest First)
2-20-2020 10:03 PM
Elsevere I know it is a bit later, but you should submit some of your photos to Airtech's website. They only have a few photos of the EX500.
1-16-2020 2:58 PM
ZeroFret Nice! Looks great.
1-15-2020 8:21 PM
Bulldog 50 Finally got her done took awhile but we got there lol. Added a couple of better pics .
12-11-2019 9:07 PM
Bulldog 50 Startin to come together pepper startin to come together. Lol was held up a few days waitin on the local shop to get me a k&n air filter. I love to spend my money locally but 78 buck is f'in steep . I ate it and carried on after a few snyed remarks. Oiling one of them with what comes with it is a chore in of itself . This is what we got so far .
12-7-2019 2:57 AM
Bulldog 50
Quote:
Originally Posted by willi777 View Post
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
I feel ya the bike in my profile pic was 12hung. Was putting the full lower on no matter what then we cracked the deer lol, but once u get to 3 parts in need of paint why not just paint the other 3 lol. i do have the benefit of having a pro paint and body guy for free. just so it's clear I did everything but the spraying .
12-6-2019 9:08 PM
willi777 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
12-6-2019 8:53 PM
Bulldog 50
Quote:
Originally Posted by willi777 View Post
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
12-6-2019 8:20 PM
Bulldog 50 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.
12-6-2019 9:40 AM
willi777 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
12-5-2019 9:06 PM
Bulldog 50 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.
11-30-2019 6:27 PM
Goggles 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
11-29-2019 8:49 AM
jorge moros
Quote:
Originally Posted by Bulldog 50 View Post
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.
11-28-2019 12:32 PM
Bulldog 50
Quote:
Originally Posted by jorge moros View Post
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.
11-28-2019 9:13 AM
jorge moros Nice color!
11-27-2019 8:18 PM
Bulldog 50 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.
11-20-2019 9:12 PM
Bulldog 50 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 .
11-19-2019 9:04 PM
Bulldog 50 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.
11-19-2019 8:13 PM
[email protected] 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.
11-19-2019 6:23 PM
Bulldog 50
Quote:
Originally Posted by po18guy View Post
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
11-19-2019 6:00 PM
po18guy 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.
11-19-2019 4:50 PM
Bulldog 50 Sorry when I mentioned the reveal I was talking about the headlight. The rest is pretty much predetermined
11-19-2019 4:49 PM
Bulldog 50
Quote:
Originally Posted by jluva007 View Post
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 .
11-17-2019 9:21 PM
jluva007 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.
11-17-2019 9:50 AM
K-woppa That sounds like a cool color. I'm interested to see the final product.
11-16-2019 10:38 PM
Bulldog 50 Pics didn't want to load.
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