Cam / Sprocket Cover Chop - Questions!

[Randum77]

Ok, so I am tossing around the idea of cutting up the Sprocket and Cam cover. I really am becoming less and less of a fan of the way it looks stock and really liking the ones i've seen floating around of them cut up. I've just got a couple questions...

1. I want to keep my back break resivour where it's at. How'd you all cut yours on the pre 04' so that you could keep it?

2. What tools did you end up using? I've got an air compressor, 3" cut off wheel, 5" grinder, and some misc other tools. I don't have access to a nice band saw sadly, or i would use that. What did you use to cut up yours?

3. Anything to watch out for, or any "costly" decision i don't need to make?

-Marshall

[vert306]

sounds like you got the tools. grinders should work fine. turn the cam cover over, it'll give you your outline to follow on the cuts. take your time. the sprocket cover is similar, turn it over and you can decide which way to go with it based on the webbing on the back. you can take as much or little as you want around the master cylinder that way. best of luck and post it up when done!

[Preacher]

I used a die grinder and cutoff wheel, then a flap wheel. Just go for it.... worst case scenario, a new set is about $150 at Zanotti.

[hybriDatsun350]

Originally Posted by Preacher

I used a die grinder and cutoff wheel, then a flap wheel. Just go for it.... worst case scenario, a new set is about $150 at Zanotti.

So I guess it's not too expensive of a screw up, haha.

[Randum77]

Thanks for the info. I'll probably do some photochoppin' to get an idea of what I want to do to the covers. I might wait till I get my new digital camera to do the work so I can document it and post it up to help out here. I thought there was a "chopped bike pictures" thread but I can't find it right off. I figured it'd be good fer idea's. I'll dig around a bit more.

[Moved On]

Hey Randum about friggin time you did this

I used a hack saw for the cutting, then a sanding disc on my angle grinder for smoothing it out, and lastly the dremel tool and a round file for getting into the curves and taking the edges off the bolt recesses.

You may run into one oil passage void on the bottom of your cover. Some of the covers have a hole in the bottom from tooling the covers which opens up when the cover is cut. If my memory is right it's around the same year as your bike that this might happen. If you expose a hole, then you'll need to find a self tapping screw (or JB weld) to plug it back up.

Gazza

[Moved On]

Here's a couple other threads...

http://www.xlforum.net/vbportal/foru...ad.php?t=24514
http://www.xlforum.net/vbportal/foru...ad.php?t=24842
http://www.xlforum.net/vbportal/foru...ad.php?t=28107


Gazza

[Randum77]

Originally Posted by Gary

Hey Randum about friggin time you did this
Gazza

It's been buggin me for a while now, i just finally decided to give in. I am going to have to pull the exaust since the Pro-Streets wrap all around in that area. I might just need to get some headwrap and go to town with it as well. I really don't like the heatsheilds at all. I went ahead and pulled the front fender to see how i like that for a while too. Finally, she's getting the attention she's been needing.

[jduffy01]

i actually cut one then went back to stock, didnt look as clean to me with the chopped one. i may change my mind again, who knows.

[kadmf]

I just left enough to mount the bmc back on and it turned out pretty good. I plan on just cleaning up the bottom of it a little bit more when i finally chop the cam cover