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Well it took almost a whole large can of Bondo
and a lot of sanding to get it smooth and not show the wood grain. I used Gloss Black Dupli-Color acrylic enamel
that went on easy. Dries real quick, but you need to get all the coats you want on it within one hour with about
10 minutes between coats. After an hour you have to wait seven days for it to cure before you can add any more coats. After
drying for about 4 hours I went over the whole thing with some very fine steel wool to give it a semi-gloss finish.
I found that a glossy finish made all the imperfections show up too much.
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| A heck of a lotta work later we're ready to go |
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| The extra weight is barely noticable |
Click to enlarge
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| I used some rubber washers to dampen the vibration |
I used four 6 inch heavy duty "L" braces that I got from
Home Depot. The holes in them are the right size for the stock chrome bolts that are located on the tail fender chrome
side pieces (don't know whatcha call 'em). There are three bolts on each side of the fender. Two of them
are the same height from the ground so used those so the box would sit level. One bolt goes through the "L" brace and
into the fender. The box then sits on the four "L" braces and are bolted to the box with four stainless steel machine
screws with lock nuts. You can see the aluminum extension that goes toward the back of the box that I added to give
additional support to the rear of the box. It is very sturdy. I did replace one of the bolts on each side of the
fender with a longer metric bolt that I got at Home Depot.
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| Used vinyl chrome from auto parts store to shine it up |
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| Got the rope cleats from boat store |
The chrome vinyl strips help to make it not look so homemade.
You just peel and stick 'em on. I added four vents so when I carry gas cans the fumes can get out. The covers
over the vents are those semi-round black things on the front and back up towards the top. They are made from white
plumbing PVC caps cut in half on a band saw and painted with the same paint as the box. I installed LED Hyper-Lites
for some more light up power when hitting the brakes.
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| Vinyl chrome bumper and Limited Edition badge |
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