Building My Mold... It's Done And On The Bike!

[Bill Havins]

The work has begun!  I have all of the plastic stripped off the front of my bike.  I have set aside the next six days to complete the "first mold" of my Valkyrie Fairing (I need an emoticon of a guy wearing a hard hat and sweating like crazy...).  I do not intend to take these into production, but might be willing to crank out three or four of them if the design works as well as I think it will.

Now, I don't pretend to be the "king of design."  I do okay, but don't claim to have a sense of what "most people" like.

I would appreciate it if you would either post images of, or links to, your favorite fairing design that has elements in it that might be adapted to work with our Valkyries.  I have my basic design in my head, but would like to consider the input from others to make sure I am not just designing "more fine furniture" (quote from my friend, Vladislav Gorbenko, in reference to my design style).

Thanks for your input!

Bill

[Kidd]

https://en.wikipedia.org/wiki/Motorcycle_fairing#/media/File:ZweiRadMuseumNSU_NSU-SportMax_1955.JPG

Here's my favorite fairing 

[Bill Havins]

I love it!    And it looks like it has some miles(?) on it, too.

[Firefight100]

  Yes, keep going....

[Pete]

Check out Hanigan and Vetter.

[bscrive]

I always wanted to get a batwing put on my bike.  I stopped because it would have destroyed all the mounting points with all the cutting I would have had to do and the headlight just wouldn't fit right.  

Maybe go from that design point, Bill.  I know I would be interested in something like that.


https://fortnine.ca/en/memphis-shades-batwing-fairing-140319?gclid=CjwKEAiAq8bEBRDuuOuyspf5oyMSJAAcsEyWCpb8ihiybnEVaLanYEDw89WlTHicENL4MsOFtx6OfxoCaprw_wcB

[Bill Havins]

I'm just thinking out loud here, so don't pay any attention, unless you want to watch a crazy man (with one foot nailed to the floor) spin in a circle.

So the 1800 Valkyrie, with its very competent radiators, presents a rather wide front view.  That's why I chose the F6B V-Stream windshield from National Cycle as the windshield for my fairing.  Plus the fact that the V-Stream has some pretty nice aerodynamics built into it, and it's 6mm thick polycarbonate with a Quantum coating (won't absorb water like PC by itself does).

Remember my original influence for this design is the 1956 Jaguar XK140.  It has some lines to it that remind me of the tank and other lines on our Valkyries. (So Kidd didn't realize that he was actually in the time frame that is a strong influence of where I'm headed - Good job, Kidd!).


We have this wonderful, but oddly-shaped, headlight on this scooter.  You could land an airplane with it, but, wow, what a funny shape.  It demands a "bolt-on" nacelle that is vented to protect the LED from overheating - that vent should connect in the fairing and "exhaust," blowing air up the inside of the windshield.  The heat won't be noticeable by the rider; the venting to the inside of the windshield will help to reduce head buffeting.

There should be a separate piece (an air dam), mounted at or near the lower triple clamp, that serves to seal the bottom of the fairing while directing air to the radiator inlets.  This piece should attach to the fairing after both are installed.

The fairing should mount to the lower triple clamp where the headlight presently attaches.  It should also mount with two short "rods" to the handlebars - not a lot of "stuff" to be seen up top.

Gotta' have hand protection.

The fairing should bolt together in the center.  This centerline will add rigidity.  The headlight nacelle will hide the major portion of the seam.  The fascia that covers the windshield bolts/mounts (a separate piece) will cover the rest of the seam.

Gotta' keep it light weight.

Blithering idiot...  Eat supper and get back to work in the garage.

Once I have the first "mock-up" done I'll post an image or two.

Bill

[mikesgotmods]

I'm going to suggest for someone to link photos of the batwings Corbin has made for other models. They take the batwing theme into the future quite nicely.  Also, any design will have to be short on the bottom to clear the pods at full lock. It will also have to relocate the turn signals or be slotted to slide over them in stock location. Sorry I'm not techie enough to post the links myself but just google Corbin fairing images.

[Kidd]

Sorry I'm not techie enough to post the links myself but just google Corbin fairing images.

Really , you can not do this ?
https://www.google.com/search?q=Corbin+fairing&biw=1536&bih=755&source=lnms&tbm=isch&sa=X&ved=0ahUKEwjSmpCOmvTRAhXDw1QKHQlwAzsQ_AUIBygC

[Bill Havins]

Yes, Mike, the radiator cowls are a real obstruction.  I think they're "outta' here!" on my bike.  My planned replacement radiator cowls are pretty thin - more about that later.

It's 29° in the garage this morning.  Heavy sigh....  But, I'm going back to work on the mold.  The more I play with what can be done on this scooter the more "batwing" the design becomes.  We'll see what I come up with.  And I'm pretty excited about the prospects for an air dam and venting.

Bill

[bscrive]

I think Kidd has something here.  

Looking through the images this one jumps out at me.  It has styling and looks high enough to pass the pods, or a slight modification of the pods.  A modification of the front to go over the headlight would be in order.

[Kidd]

Yeah , that would remove a lot of the wind , nice

[Bill Havins]

When I removed the headlight assembly from the front of my Valkyrie I was pleased to realize there are nice fairing mounting options built into the triple clamps.  In the photo I have "flagged" two of four 8mm stainless hex head bolts; I installed these bolts in the four holes that normally hold the headlight assembly to the front forks.  They look like a great place to mount a fairing and might eliminate the need to tie the fairing to the handlebars.



Bscrive and Kidd, as I continue to play with this (building the skeleton for the surfaces) the design is headed in a similar direction.  If you look at the hood on the Jaguar XK140 you see the same general shape.  It's beginning to come together.

Bill

[Bill Havins]

NEWS FLASH!  EXTRA!  EXTRA!  The radiator cowls may stay!

As I was getting ready to close up the garage last night I looked closely at where I was with the structure and attachments for my "buck" (the mock up that is used to make the mold).  I tried the windshield on it to check clearances all about.  And, believe it or not, it looked like everything would clear the OEM radiator cowls!  Now that would be a real stroke of luck!  Less work to get mold(s) made, and less installation hassle.

More later.

Bill

[semo97]

Just a thought can a frame mount set up be done instead of fork mount? Head light may need to be set forward a bit, then all you will need to check if your handle bars can go lock to lock. I do not have 1800 but the 1500 IS has been in the family for 10 years. I also have been on an st1300 for 14 yrs. and sheild protection can be a problem. I fabricated several shields for it and finally went with a vented 1800 wing shield and it works very well. the ST has an electric adjustable shield with a gap between it an the front fairing. I do not care for the x-creen ,spoilers or lipped shields. Lets think out of the box, most of the head buffeting seems to come from under the shield and into the cockpit. Why not fab a spoiler attached to the lower inside of the main shield say an inch out and 6 inches tall going same bend and angle as main shield. this will pick up the air coming in and force it up the shield and should be pulled up to the top. You would have to experiment with size, angle and distance out from the main shield. It may not work or it could be a quick easy fix. I also feel a vented shield opened part way helps some in buffeting.

[Bill Havins]

Here's a bit of an update for those who are interested.  I have the lower two-thirds of the buck "almost" completed.  This is very slow going; it all has to be done by hand, one surface at a time.  And I am also "capturing" the really odd and curved surface on the lower part of the National Cycle windshield I plan to use - I want it to mount precisely so I have to recreate the back side of the windshield (the concave surface) in the upper part of my buck.

I plan to re-use the turn signals.  They will mount in concave surfaces of the fairing, at just about the same height as where they mount on the OEM headlight nacelle.

The headlight (without all of its OEM plastic) will mount in a "pocket" in the fairing.  I'm planning on a more rounded trim piece; that may relieve some of the "beak look" that the headlight has in its OEM nacelle.

Once I have the buck finished, sanded, and primered I will post a photo or two.  I figure that is about three weeks away.  Unfortunately(?) I have two weekend business trips coming up this month - that "steals" a lot of my time I would otherwise use on this project.

Rock-and-roll.

Bill

[Shrubbo]

I can't wait to see this tbo

[bscrive]

Waiting to see the outcome Bill.   

[Bill Havins]

Here's a bit of an update.  I will likely have the basic shape of my fairing complete by the end of this week.  Hurrah!  I'm pleased with how it is coming along.

But I have a big question: do I try to incorporate the OEM headlight into the fairing, or do I design it to accept a "standard" 7 inch round headlight?  If I go the round headlight route I am considering installing a J.W.Speaker unit like this:  https://www.jwspeaker.com/products/adaptive-led-headlights-model-8790-adaptive/ .

Please let me know what you think.

Bill

[hubcapsc]

Go round.... put on a "normal" looking headlight and then
post all the details about how to do it 

-Mike

[Kidd]

Considering the fact that you make it seem  easy , I'd go with the new head light

[Thor32]

Here's a bit of an update.  I will likely have the basic shape of my fairing complete by the end of this week.  Hurrah!  I'm pleased with how it is coming along.

But I have a big question: do I try to incorporate the OEM headlight into the fairing, or do I design it to accept a "standard" 7 inch round headlight?  If I go the round headlight route I am considering installing a J.W.Speaker unit like this:  https://www.jwspeaker.com/products/adaptive-led-headlights-model-8790-adaptive/ .

Please let me know what you think.

Bill

Keep the OEM- it is a positive feature of the uniqueness of the bike and sheds good lighting!

[Bill Havins]

Thanks for the thoughts.  I decided to go round and ordered this one with a chrome bezel: http://www.jwspeaker.com/products/led-headlights-model-8700-evolution-2/ .

Yes, the performance of the OEM headlight is very, very impressive, but the more I studied it I just couldn't see trying to accommodate it in the fairing design.

So, onward we go.

Bill

[bscrive]

Bill, have you thought of dual headlights?  BTW, I really like the look of the headlight you chose.   

[Bill Havins]

I did briefly consider dual headlights and then had to vote against it.  As it is I am to the point where I'm "scrambling for real estate."  In other words, finding space where everything looks "right," and keeping the size and weight like I want, is becoming a challenge.  But I'll get there.

Now it's off to the surgeon to check my damaged finger.  HF drill bits are no bueno.

Bill

[Kidd]

Think about recessing small powerful lights into the fairing , you can do it

[Bill Havins]

It's 44° F in the garage this morning.  I came back in to warm up before going back out.  I thought I'd pass along my random thoughts about designing this fairing.  I'm pleased with where it's headed.

So I ordered my J.W. Speaker Evolution 2 headlight and a J.W. Speaker mounting ring set.  They are here - nice pieces!  It is interesting how much the headlight and my Honda running lights resemble each other.  That will help to "unify" the fairing design with the cowling on the bike (sometimes you "luck out").
http://powersports.honda.com/images/accessories/c106_116_accessories_all/pop_ups/08V70-MCA-S41.jpg
http://www.jwspeaker.com/products/led-headlights-model-8700-evolution-2/

The next question was, “What sort of trim ring do I put on the headlight?”  I can’t just have the thing sticking out in front of the fairing with the mounting ring exposed.  This began a two-day quest.

I quickly decided that I didn’t want to design my own.  It needed to be made of metal (given the abuse such things experience) and that would end up as a $500 piece if I designed it myself and then either machined it myself or had it done.  Nope!  That was a blind alley with a billfold mugging at the end of it.

I visited with my parts manager at my Honda dealership and the best options we could come up with were in the $50+ range.  I figured I could find something better and cheaper.  And there was also my desire to have a bit of a “retro sports car look” to my bike’s final design.

After scouring the internet for the past two days I ordered this:  https://www.crownautomotive.net/Headlamp-Bezel/J0649518.html

It is a headlight bezel used on Jeeps as early as 1946 (through 1971) and its mounting system appears to match the J.W. Speaker mounting ring set perfectly.  Score!  A “splash” of chrome in the middle of this gloss-black fairing.

This morning I plan to finish the headlight nacelle portion of the fairing model.  Then its on to the hand protection, a lot of sanding and final shaping, and the initial design work will be done.

Okay.  Back into the cold….

Bill

[Kidd]

Yeah , there's lots of them headlight bezels out there for sale ,lot's to pick from

https://www.google.com/#q=headlamp+bezel&tbm=shop

[Kidd]

Also , headlight  housing , too

https://www.google.com/#q=motorcycle+headlight+casing&tbm=shop&*

[Kidd]

Nice video about JW Speaker head light
http://www.jwspeaker.com/blog/new-led-motorcycle-headlight-adapative/?gclid=Cj0KEQiA0L_FBRDMmaCTw5nxm-ABEiQABn-VqToRQtepnm3XnlqqlaUM66VvyZWkRkM54GD3byAOenEaAiMR8P8HAQ

[Bill Havins]

Yes, the Speaker "Adaptive" headlight is amazing.  But it's a big price tag.

To get started with this fairing I wanted to use a 7" headlight - many options out there for great headlights in that size.  And I wanted to use a J.W. Speaker unit; IMHO they are the best.

So, since this is a "first attempt," I chose an Evolution 2 unit to get an excellent headlight while keeping the price as low as I could.

We'll see (pardon the pun).

Bill

[Bill Havins]

 Okay.  I have an "unusual" question for those who have been following my work to design a fairing for my Valkyrie.  By late Monday I plan to have the first "rough-in" of my master model done.  Do you want to see images of it, or would you prefer to see it when the model is "done" (i.e., painted with a glossy finish and ready to use to create the mold)?

If I shoot images late Monday the model will be "splotchy" with patches of filler (it will look like what I call a "spotted dog").  The shape will be complete and I'll have the headlight and trim ring mounted in place.  I will try to have the windshield installed, too.

I likely won't wash my bike; it will be covered in sanding and modeling dust.  And the shots won't be like "studio shots" - they'll simply be "snapshots" taken in my garage.

One other caution - remember my inspiration is a 1956 Jaguar XK:


I have kept the radiator cowls intact.  The design works very nicely with them and presents a real "unified" look to the front of the bike (IMHO).

So, what do you think - images late Monday or when it's completely ready to mold?

Please send me a PM if you don't want to express your thoughts "publicly."

Cheers!

Bill

[bscrive]

Bill, I would like to see how it looks now. 

[Verismo]

Definitely want to see the progress pics!

[kcole683]

I am looking forward to seeing this fairing come to fruition as well.

[Bill Havins]

Thanks, guys.  If I don't wear myself out between now and then I'll have photos up sometime on Monday.

Bill

[Bill Havins]

Well.  I promised snapshots of my fairing design by the end of the day today.  I got a bit behind.  I am not normally willing to show a design this early in the process but we’re all friends here, right?  So here are the snapshots.

As you look at these you will notice I didn’t get the windshield trimmed and mounted.  The second shot gives you a sense of what the windshield will look like when it is in place (look closely for the screw I have holding it in place on top of the headlight nacelle – nice touch, eh?).

You will also notice I do not have the turn signals mounted – it is obvious where they go.  And the headlight is not mounted.  But you can get a sense of what it looks like in the links in earlier posts in this thread.

And you’ll see lots of putty and filler that remains to be sanded.  And there are surfaces that need to be rounded and faired.  Such is the life of a project at this stage.  But I think you can get the sense of where I’m headed.

As you look at the images you’ll notice I have boxed in the triple clamps – this should stop some air flow.  The fairing does turn lock-to-lock without hitting the radiator cowls.  At the bottom, just below the headlight nacelle, is a “scoop.”  This will vent to the back side of the windshield, hopefully reducing buffeting.  The scoop will also cool the LED headlight.

As you look at the fifth image you’ll see the leading surface of the fairing is in front of the leading edge of the radiator cowl.  I am hoping this, combined with the “boxing” of the triple clamps and the design of the radiator cowls, will present a “single” surface to oncoming air, adding to the “aerodynamics” of the fairing.  Oh, heck!  Who knows how it will work until I have it on the road.

Front view (almost):


Front view with untrimmed windshield held in approximate place (look for the screw – a real touch of class!):


Side view (look at all that filler!):


Handlebars at full lock to left (it clears the radiator cowl!):


Side view showing leading surface of fairing is in front of the leading edge of the radiator cowl:


Please remember I am building the model just to get “the surface” – all of the support structure of the model means nothing as far as the mold goes.  The mold will just capture the forward-most surface.

Enough of this – I’m tired.

Cheers!

Bill

[bscrive]

Bill, I think it is coming along nicely. 

[_Sheffjs_]

You should be tired!  That is a lot of work you have done.   I believe you are on to something here and we continue to yearn for updates.  I think the next one will paint a clearer picture for me.  

Question. Will you be running a different front light?

[Bill Havins]

Thanks, Brian.

Yes, _Sheffjs_, I have a J.W. Speaker Evolution 2 7" headlight I'll be using (see posts about this earlier in the thread).  If the fairing works well I will eventually change to a J.W. Speaker "Adaptive" 7" headlight.  But that is an $800 price tag, so the fairing has to be working really well for me to make the change to that!

Bill