Phazer Builds 3

 As we wait for some parts to come in for the engine end of the build we decided to move onto the skid

 After closer inspection we discovered the front lower portion of the arm was cracked right through, so we will be repairing that.

 We have also decided to do away with the steel springs and build a custom rear arm and spring setup

 We will also be eliminating the whole aluminum block/pivot point

 Here is the rear are removed

 We are still going to use the lower pivot point and attach our new arm and shock setup to it

 This is as far as we are taking the skid down for now, this way we can build our new arms and fit them, then we will take the skid right apart and send it off to powder coating with the rest of the completed parts

 Onto the tunnel, the boards on these machines need some serious upgrades

 The rear portion on the tunnel is also weak once you remove the steel so we are marking off where we are going to remove it.

 Another angle of where we are going to cut, we like to use tape, makes it easy to mark out and follow

 Obviously doing the same to the other side

 Here is the first board cut off

 We left a bit of a lip on the tunnel, this will act as a tie in/support for the new running boards

 Both boards cut off

 Both boards and the rear section of the tunnel remove!

 Now were having fun

 All cleaned up and ready to move on to making the rear portion of the tunnel, we could have built a complete new tunnel, however we didn't see much of a benefit as we would have simply had to duplicate the front portion anyways.

 Even though we have high tech 3d modeling software, sometimes you just have to break out the good old construction paper and build a template!

 Here we are laying out the template, next scissors. Arts and craft time at Simolo Customs

 There's the template, ready to put it to metal

 Another shot to get the whole machine in

 Now we lay the template on the piece of aluminum we just sheared

 We have predetermined reference marks that we have laid out, this was determined from the test pieces we did last week

 No fancy tools for this, just used a band saw, you can see in this photo it's still not completely cut out

 Here it is rough cut and ready to be formed on the press brake, once it is formed and we do a test fit we will then do all the finishing work. We don't want to spend hours finishing the material if we find out we don't like it or if it doesn't fit.

 Here we are making the first bends on the tunnel which are the least of the two angles, we are matching the Yamaha factory tunnel

 You can see both bends are the same now to move onto the final two bends

Here it is back in the press brake, bending the second set of big angles

 A picture from the back side to see what's going on

 Second side getting the same treatment

 We are happy with the look of it

 Now to see if it fits

 Fits awesome

 We like the look of it, and once it is powder coated you will never know it is two pieces

 Nice and square, it fits so tight that it holds it self in place

Now it's time to clean the tunnel up, do all the finishing work, finish the back of the tunnel, and then attach it to the front portion of the tunnel. We can then drill the skid attach points and build the running boards. 

If you haven't seen the start of this build head here  | Phazer build|