Crash bars for my 2015 650 - Kawasaki Versys Forum
 
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post #1 of 18 (permalink) Old 07-09-2015, 05:39 PM Thread Starter
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Made a set of crash bars for my 2015 650

Every time I want to order some thing they tell me 6 to 8 weeks possibly longer.
So here I am again making some thing else for my Versys

Used what I had laying around except some aluminum spacers and longer bolts

Here is what I came up with for the first set

right side I need to do some adjustments on this one






left side


Last edited by Motojunkee; 07-10-2015 at 11:46 AM.
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post #2 of 18 (permalink) Old 07-09-2015, 06:31 PM
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Very nice. I wish I had your skills with metal. My talent extends only to polishing to retard the dreaded rust.

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post #3 of 18 (permalink) Old 07-09-2015, 07:36 PM Thread Starter
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The way I got the skills was making small things like this


Tools that I used
1 110 volt welder made by miller with flux core wire no bottle need for gas
you can rent a 110 volt welder from home depot or lowes

looks like this



1 4 1/2 inch grinder mines a makita but can be had a harbor fright on sale for $20 for a cheap one. get the 4 1/2 not the 4"



small harbor freight drill press my friends hand drill would work also



pipe bender from harbor fright buy it on sale or look for used one.

This takes practice to get good with




sharpy markers
Vise
Vise grips
hack saw
drill bit assortment
center punch
tape measure
cheap vainer caliper for lay out for drilling holes accurately 6 inch harbor fright
4 1/2 grinding wheels
4 1/2 cut off wheels
4 1/2" sanding flap wheel to clean up edges
1/2 inch black pipe home depot

My local metal yard has a 5 foot minimum per piece
1" x 1/4" x 5' flat stock local metal yard can buy at home depot but expensive
2" x 1/4" x 5' flat stock local metal yard can buy at home depot but expensive
2" x 1/4" x 1 foot angle iron had this laying around
1 1/4 round aluminum round stock to make spaces need 4 at 42mm long
had to drill hole down the center wished I had a lathe to work with but drill press worked
good hard ware store for metric bolts and nuts
spary paint


The main reason I bought the welder was to build a bumper for my Suzuki samurai 4 wheel drive
the bumper at the time where over $700 each
welder was $500 and other tools may be $300. meterial cost at the time $200

So I saved $200 and learned how to weld with a father and friend showing me a little bit on how to weld

local collages or vocational schools offer a beginning welding classes. this is where my friend learned in collage

Last edited by Motojunkee; 07-09-2015 at 07:48 PM.
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post #4 of 18 (permalink) Old 07-09-2015, 07:47 PM Thread Starter
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post #5 of 18 (permalink) Old 07-09-2015, 07:49 PM Thread Starter
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If you have any thing like this
you can learn and use there tools for a fee
Tech -shop
http://www.techshop.ws/

http://www.techshop.ws/austin_round_rock.html
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post #6 of 18 (permalink) Old 07-09-2015, 08:10 PM
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Impressive, and a great collection of tools but beyond my DIY skills. And I'd have to be incredibly good for a long time to convince my charming wife it's time for yet more cool equipment. In my case it would be less expensive to buy SW Motech crash bars (for my '08 model). One nice thing about owning an older model.

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post #7 of 18 (permalink) Old 07-09-2015, 10:39 PM
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Garage
Send a message via Skype™ to silviefox
now are you going to test them for us? if you do do it on video

yes im a guy.
Silvie=latin for. Of the forest /woods. Fox= Vulpine (also my middle name)

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post #8 of 18 (permalink) Old 07-10-2015, 07:15 AM
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what are they bolted to?

might make something similar for my 08, but it will likely have to clamp to the frame
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post #9 of 18 (permalink) Old 07-10-2015, 08:34 AM
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Impressive!
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post #10 of 18 (permalink) Old 07-10-2015, 11:03 AM
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Very nice work!

I too ran into the problem of getting crashbars for a '15 model. I have a welder, but not the time during the summer. I found that Hepco-Becker had some available, and ordered a set. I was told there was a 6-8 week leadtime, and I resolved to wait. Less than a week later, I got an e-mail notification that they had shipped, and should be here early next week!
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post #11 of 18 (permalink) Old 07-10-2015, 11:26 AM Thread Starter
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Originally Posted by RDJeff View Post
Very nice work!

I too ran into the problem of getting crashbars for a '15 model. I have a welder, but not the time during the summer. I found that Hepco-Becker had some available, and ordered a set. I was told there was a 6-8 week leadtime, and I resolved to wait. Less than a week later, I got an e-mail notification that they had shipped, and should be here early next week!
Nice
That is what I have been hearing as well 6 to 8 weeks possibly longer, from all companies for accessories
I made these till then. We will see what the market brings out.
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post #12 of 18 (permalink) Old 07-10-2015, 11:35 AM Thread Starter
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what are they bolted to?

might make something similar for my 08, but it will likely have to clamp to the frame
On the 2015 they redesigned the motor mounts with rubber dampeners .
on either side uf the rubber dampener there are two holes these are what I
This is where Kawasaki mounts there frame sliders

For the 08 I would look at the sw-motech cages nice design work well in a tip over . did not do to bad in my accident as well when I went to wide in a corner and hit the side of a Toyota Carrola

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post #13 of 18 (permalink) Old 07-10-2015, 11:45 AM Thread Starter
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Originally Posted by RDJeff View Post
Very nice work!

I too ran into the problem of getting crashbars for a '15 model. I have a welder, but not the time during the summer. I found that Hepco-Becker had some available, and ordered a set. I was told there was a 6-8 week leadtime, and I resolved to wait. Less than a week later, I got an e-mail notification that they had shipped, and should be here early next week!
Please post a photo of them. Interested to see what they came up with. they make some nice products. I have not been able to find a photo of theres
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post #14 of 18 (permalink) Old 07-11-2015, 02:17 AM
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I'll post a photo when I get them on, but you can see them on their site.
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post #15 of 18 (permalink) Old 07-13-2015, 11:47 AM Thread Starter
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I'll post a photo when I get them on, but you can see them on their site.
I contacted http://www.hepco-and-becker-luggage.co.uk/ and asked for a photo of the guard here is what they sent me looks good but I would like to know where they attach the upper part to. as the stock fairing support is not very strong materiel.
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post #16 of 18 (permalink) Old 07-13-2015, 12:27 PM
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Thanks - I BELIEVE I'll put an SW-Motech on mine, as the H-B appears to leave the lower part of the engine cases TOO exposed.

Ed
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post #17 of 18 (permalink) Old 07-13-2015, 12:44 PM Thread Starter
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The new sw-motech bars for the 15 are going to look like mine
They are located higher on the fairings.



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post #18 of 18 (permalink) Old 07-13-2015, 01:07 PM Thread Starter
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Been thinking about adding these covers for the cases



Last edited by Motojunkee; 07-13-2015 at 01:14 PM.
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