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-Big Al
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Fender Cutting & Tail Light Removal

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Posted 28th June 2010 at 14:22 by Big Al-1200c

Fender Cutting & Tail Light Removal

!The XLFORUM.net blog only allows 4 pics, to see all of the pics in detail, please click the link above to be taken to the original article.!

Now that the Run, Stop, Turn Signal Module has been installed, we move into cutting the fender.


Here is the digital muck-up I did, trying to decide where to cut the fender.


I removed the fender to remove the tail light and move the wiring and support bracket out of the way.

(IMAGE)

This is the Tail Light Base that contains the Circuit Board we need for later. Disconnect the wires and carefully pry it outwith your hands or a wooden tool.

(IMAGE)

Note on the picture to the right, that the fender support bracket and harness are in the way of the cutting line. The harness was moved back and will be relocated later, the bracket on the other hand, since I want to retain it for 2 up riding support, needs to be moved.

(IMAGE)

To do that, just flip it, so that it hangs towards the front of the fender instead of the rear. Now the harness support tabs notches are in this new location, preventing the bracket from laying flush against the fender.

(IMAGE)
A quick cut with the dremel and that is taken care off.
Now the bracket can lay flush against the fender.

(IMAGE)

Stand back, I have not dusted the ol' Dremel in a few years! (and I call myself a man?), so my hands are a bit rusty. I have to say I recommend a 3" cutting wheel instead of the Dremel, as that will probably take 5 minutes, took me 25 minutes with the Dremel. Use blue painters tape or similar to protect the cutting area, making sure it is tight and without bubbles. Use a pencil to mark your cutting line and measure to make sure you are even. All up to this point, you can change your mind and go back, but once you put the dremel to the fender you are committed, so make sure you got the line and contour where you want it. Once done, I used a stone to remove sharp edges and even out any imperfections.

The cut came out clean and straight.


(IMAGE)(IMAGE)(IMAGE)

Up next,
License Plate Relocation
Mounting the circuit board under the fender, plus routing the wires.
Paint

-Big Al
Posted in Uncategorized
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Comments

  1. Old Comment
    Epyx's Avatar
    Good post, thanks for the effort. I am going to use this in the future. Not on my XLN but on a Yamaha project bike I may start working on some day.
    Posted 7th July 2010 at 11:49 by Epyx Epyx is offline
  2. Old Comment
    this is a great blog I'm going to be doing the same hing to my 883 thanks for the info
    Posted 18th May 2011 at 14:19 by rikasso
 


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