Ben's VF750 # 3, rear wiring cover, electrics box

[Prof]

Back onto Ben's VF 750...
First job is to finish taillight and run a brass rib over the rear guard for the wiring.

Ben supplied some brass angle which we narrowed with an angle grinder and then bent in the vice just like we do flat bar (pis in other places of this process).

Where the brass goes under the taillight mount, it is shaved off...


Now need to protect the wire as it runs form the taillight to the brass bar. After looking at a few options, I settled on a piece of bent tube. This I'll cut out of a length of car petrol line...


Tubing is weled to taillight mount and locates into a hole in the brass bar. It is not welded to the brass although it appears so in this pic.


View from the rear. Wiring can now travel through the brass across the top of the guard to emerge under the seat...

Taillight bracket is a bit skewiff. I'll staighten in up tomorrow. Guard looks crooked too, but it is partly the angle and also it is not bolted up yet as I still have to put a small tube through the rear frame cross member or the wiring to travel through.

[Prof]

Electrics Box was done some time ago. Here is how it was done...

First step is to make up a template. I use alumiumcaravan siding because it holds its shape especially bends.

Measure up one set of dimensions (in this case the lengths)...


Now fit in and measure and cut the second (width) set...


Try the components for fit and note any modifications/tabs needed...


Measurements transferred to 3mm steel plate and out with the angle grinder (sure beats the hacksaw I had to use when I begon chopping bikes...


Curves can be cut with progressive triangular slices of the angle grinder


Or you can save those 'worn out' cutting discs and use them like this...


Next step is to make the battery hold downs. This side incorporates a strengthening bar across the battery holder...


These tabs are for electrics box. They have nuts welded to them. A third tab is welded to the right hand seat rail...


Regulator hangs in the breeze under the battery/electrics mounting. Bolts are welded in after being countersunk. The mounting has been heated and the holes punched so nothing protrudes to damage the bottom of the battery...


Now for the electrics box. This is an old three phase fuse box from my collection, which caught Ben's fancy. Long lever will be used to operate ignition switch...


Inside the cover showing the tab we will modify to move the ignition switch...


Tab chopped up, just needs a slot to locate the switch...


Tab done. Some rectangular section will be just the ticket for making a switch bracket. The lid has also been hinged rather than just sitting on. this is necessary because there will be wires in the lid as well as the box...


Switch bracket shaped and welded in.


A view of the finished box. Lid also contains the fuse box which feeds the connector block with ignition, starter, lighting and accessories circuits.

The igniters are held in place with velcro. The starter solenoid rests on an L shaped tab and is held by a hose clamp. Holes an slots have been made in the back of the box for the wiring. You can just see the light switch at the top rear behind the connector block.

Positioning these components took an hour or so. Ben needs to be able to easily access and or remove each component and get to each connection especially on that dark rainy night 100 miles from anywhere!

[KeithinSB]

As always....
Great Job Andrew!
I really enjoy your posts here!

[El Skitzo]

Very nice work!

[Prof]

Hey Keith what projects have you been up to lately?

[Rayman]

nice to see some movement on it prof -

maybe I should post up my progress - ....

Rayman

[KeithinSB]

Hey Keith what projects have you been up to lately?

Mostly weed abatement and work here lately.
We did get to a couple GREAT motorcycle events though.
I will work on getting some pictures up this week.

[Prof]

Go for it Rayman, look forward to your pics Keith.