This tutorial involves a brief explination and a jpeg,Abit like a haynes manual but filled with spelling mistakes..Ha Ha .

So Lets Start By removing the rear wheel and inspecting the rear break assy Bracket ,,You can see the lugs are there but no fixing holes
1/ http://193.116.26.75/uploaded/DCP_5253.JPG
2/ http://193.116.26.75/uploaded/DCP_5256.JPG

As i didnt own a tap and die set i decided to drill holes and add nuts and bolts ,, This way needed the head of the boltd to recess in the bracked to give good clearence , Once the holes were drilled i inserted the bolts and drew around the heads , This gave me a mark to work to with the DREMMEL ,
1/ http://193.116.26.75/uploaded/DCP_5257.JPG
This method not only sunk them in but also locked the nut head in place so i could use nylon locknuts the other end
2/ http://193.116.26.75/uploaded/DCP_52650.JPG

So now im able to afix a guard of some sorts , WHAT shall i use ..
The only reason i did this project was because im tight and didnt want to spend £40 on a billited one ,Custom built one offs are allways cool anyways

So i sorsed the metal (alloy) and the shape (quarter of a circle) and with a lip built in for £3.99 this is what i came up with,,dont laugh till the end of this tutorial
1/ http://193.116.26.75/uploaded/DCP_5268.JPG
Things to remember at this point
1,Thickness of the alloy used in the pan ,
2,Size of the base , 28cm for this type of pan worked fine
3,the angle of bend you want to curl over disc when inplace
Raw form http://193.116.26.75/uploaded/DCP_5269.JPG

As you can see , All i have to do now is make a template.. Use a piece
or card for this ,
1/ http://193.116.26.75/uploaded/DCP_5272.JPG

I used a spair disk to eye things up
1/ http://193.116.26.75/uploaded/DCP_5273.JPG

Using the break disk assy bracket and the new holes as a starting point
fix the piece of card at this point and fit it to the bike , Press on the card to make a slight impression from the rear disk and map out your shape
as you can see on mine ive gone most the way round and decided not to drill patterned holes as i like the non stick look ,,LOL
1/ http://193.116.26.75/uploaded/DCP_5274.JPG

A fine tune was need because the bracket would'nt slide on the swingarm ,
I just chopped abit off along the top and it freed up
1/ http://193.116.26.75/uploaded/DCP_5276.JPG

Here are the last two photos of the finished guard fitted on the bike ,Now the holes are there i can make as many different types as i like as i saved the template.. Ill choose a thicker pan next time ,, Maybee 4 to 5 mill

Fin 1/ http://193.116.26.75/uploaded/DCP_5283.JPG
fin 2/ http://193.116.26.75/uploaded/DCP_5286.JPG
fin 3/ http://193.116.26.75/uploaded/DCP_5282.JPG

Remember , It cast £3.99 and took 3 Hours to finish

nice 1 looks good that mate and another bonus is with it being non stick the poo will just slide off it!!
mick

hey i didnt type poo whats goin on there then?

That look ok and only £3.99 i have gota have a go at doing one on me days off.

Job well done crmr. I gotta have a go at making one. Thanks for the info. What's our next project then?

probably wont stand up to seriouse motorcross but would look trick on a road supermoto.

My next project is :-

How to fit a 1200 bandit engine to a crm frame

A guy who can make a pukker disc guard out of frying pan, is capable of anything.

cool ,but the mrs is going to flip when she cant find our wok

speechless!!!!!!

lol

i bet if you use a jamie oliver pan - the mud wont stick!!!!!!