Late model shrouds on an 03+ Hybrid
- Biggles
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Late model shrouds on an 03+ Hybrid
Thought I'd do a step by step of how I fitted the 06-08 450f shoruds to my 04 Hybrid.
I searched a few forums and the best starting point is the shroud. 06-08 shrouds nearly line up with the tank bolts and is the easiest to make fit. Other models require adaptors to be machined for the top tank mount and as such it was put in the too hard basket....
The blank canvas
06-08 shroud - I scored a NOS set for $60NZD delivered
I searched a few forums and the best starting point is the shroud. 06-08 shrouds nearly line up with the tank bolts and is the easiest to make fit. Other models require adaptors to be machined for the top tank mount and as such it was put in the too hard basket....
The blank canvas
06-08 shroud - I scored a NOS set for $60NZD delivered
- Biggles
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Late model shrouds on an 03+ Hybrid
Step 1
I had a metal lock nut welded to the standard radiator support bracket to line up with the shroud hole and made a small aluminium bracket for the bottom of the radiator
Step 2
Elongate the top tank mount hole (had just drilled but not finished with the round file)
I had a metal lock nut welded to the standard radiator support bracket to line up with the shroud hole and made a small aluminium bracket for the bottom of the radiator
Step 2
Elongate the top tank mount hole (had just drilled but not finished with the round file)
- Biggles
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Late model shrouds on an 03+ Hybrid
Step 3
Need to trim a small section off the bottom of each radiator flute
(note - each side is slightlt different so measure twice, cut once )
Step 4
You need to trim the inside bottom lip off the shroud where it rests against the tank so the shroud sits a bit more flush
I trimmed the black marked area off....
Need to trim a small section off the bottom of each radiator flute
(note - each side is slightlt different so measure twice, cut once )
Step 4
You need to trim the inside bottom lip off the shroud where it rests against the tank so the shroud sits a bit more flush
I trimmed the black marked area off....
- Biggles
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Late model shrouds on an 03+ Hybrid
Step 5
Attach brackets
(yes I know the alu bracket could be a bit neater and intend to make some more shortly - this was a test run)
Step 6
Fit shroud
Please note - this is the way I went about fitting up the shroud and seemed easier than most who make a new rad support arm etc. The shroud tucks in nice and tight and looks like I was hoping. Other people may have different fittment methods but each shroud took an hour start to finish (except paint time, including weld time). Later model ones would be nice but from what I understand none of the holes line up. At least with these three (if you include the nut welded directly to the rad support arm) line up really close....
Attach brackets
(yes I know the alu bracket could be a bit neater and intend to make some more shortly - this was a test run)
Step 6
Fit shroud
Please note - this is the way I went about fitting up the shroud and seemed easier than most who make a new rad support arm etc. The shroud tucks in nice and tight and looks like I was hoping. Other people may have different fittment methods but each shroud took an hour start to finish (except paint time, including weld time). Later model ones would be nice but from what I understand none of the holes line up. At least with these three (if you include the nut welded directly to the rad support arm) line up really close....
- Biggles
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Late model shrouds on an 03+ Hybrid
The finished product
- Tedh98
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Re: Late model shrouds on an 03+ Hybrid
Nice write-up and pics.
I'm waiting for some 450F shrouds to show-up, should be here tomorrow. I was sent 250F shrouds by mistake and as you indicated, with the tank holes being off it would take the project to a new difficulty level. Not even sure how you'd get the upper tank hole to bolt up without sticking out.
I'm waiting for some 450F shrouds to show-up, should be here tomorrow. I was sent 250F shrouds by mistake and as you indicated, with the tank holes being off it would take the project to a new difficulty level. Not even sure how you'd get the upper tank hole to bolt up without sticking out.
- diymirage
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Re: Late model shrouds on an 03+ Hybrid
completly off topic but what in the world is going on with your garage floor ?
i mean, you can SEE it
i know i have a floor in my garage, i seen it when i moved in, but i havent seen it in years
i mean, you can SEE it
i know i have a floor in my garage, i seen it when i moved in, but i havent seen it in years
newbbewb wrote:DIYmirage has it right.
-1996 KDX 200 woods weapon (converted to 99 green body)
-1996 KDX 200 plated street toy (barney edition)
-2003 Yamaha TTR125-L (wifeys bike)
-1997 KDX 220 project bike
- Biggles
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Re: Late model shrouds on an 03+ Hybrid
Ha, the wife asks the same thingdiymirage wrote:completly off topic but what in the world is going on with your garage floor ?
i mean, you can SEE it
i know i have a floor in my garage, i seen it when i moved in, but i havent seen it in years
- Tyl3r
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Re: Late model shrouds on an 03+ Hybrid
bike looks awesome man! and yea lol sweet garage too!
04/05 KX220 Hybrid all decked out
18 KTM 500 EXC-F Dual Sport/Sumo toy
24 KTM 300XC-W Cheater bike
18 KTM 500 EXC-F Dual Sport/Sumo toy
24 KTM 300XC-W Cheater bike
- Tedh98
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Re: Late model shrouds on an 03+ Hybrid
I finally got the shrouds on my hybrid. It took three tries on eBay to finally get 450F shrouds.
I liked your idea of welding the nut on the radiator braces, but that wasn't going to work in my case. So I made new braces out of 1/4 aluminum.
I also made these off-center washers to cover and clean-up the lower tank mounting hole.
I liked your idea of welding the nut on the radiator braces, but that wasn't going to work in my case. So I made new braces out of 1/4 aluminum.
I also made these off-center washers to cover and clean-up the lower tank mounting hole.
- diymirage
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Re: Late model shrouds on an 03+ Hybrid
Tedh98 wrote:I also made these off-center washers to cover and clean-up the lower tank mounting hole.
not that i really like
newbbewb wrote:DIYmirage has it right.
-1996 KDX 200 woods weapon (converted to 99 green body)
-1996 KDX 200 plated street toy (barney edition)
-2003 Yamaha TTR125-L (wifeys bike)
-1997 KDX 220 project bike
- Biggles
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Re: Late model shrouds on an 03+ Hybrid
I also made these off-center washers to cover and clean-up the lower tank mounting hole.
[/quote]
Nice job, think I'll steal the off centre washer idea
Hopefully I get to ride mine this weekend.....
[/quote]
Nice job, think I'll steal the off centre washer idea
Hopefully I get to ride mine this weekend.....
- Biggles
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Re: Late model shrouds on an 03+ Hybrid
Hey TedTedh98 wrote:I finally got the shrouds on my hybrid. It took three tries on eBay to finally get 450F shrouds.
I liked your idea of welding the nut on the radiator braces, but that wasn't going to work in my case. So I made new braces out of 1/4 aluminum.
I also made these off-center washers to cover and clean-up the lower tank mounting hole.
As my hybrid is now in pieces again, am toying with the idea of grafting a complete 08 450f back end onto mine. Already started searching for an airbox, side covers etc so we will see where this ends