• Hi everyone,

    As you all know, Coffee (Dean) passed away a couple of years ago. I am Dean's ex-wife's husband and happen to have spent my career in tech. Over the years, I occasionally helped Dean with various tech issues.

    When he passed, I worked with his kids to gather the necessary credentials to keep this site running. Since then (and for however long they worked with Coffee), Woodschick and Dirtdame have been maintaining the site and covering the costs. Without their hard work and financial support, CafeHusky would have been lost.

    Over the past couple of weeks, I’ve been working to migrate the site to a free cloud compute instance so that Woodschick and Dirtdame no longer have to fund it. At the same time, I’ve updated the site to a current version of XenForo (the discussion software it runs on). The previous version was outdated and no longer supported.

    Unfortunately, the new software version doesn’t support importing the old site’s styles, so for now, you’ll see the XenForo default style. This may change over time.

    Coffee didn’t document the work he did on the site, so I’ve been digging through the old setup to understand how everything was running. There may still be things I’ve missed. One known issue is that email functionality is not yet working on the new site, but I hope to resolve this over time.

    Thanks for your patience and support!

Crash Test Dummy

HARDER1 said:
I think I can salvage my lower shroud. I'm in the midst of a JB Weld science project with all the broken plastic brackets. The two main upper rad mounts are next. Those are integral to the whole Rad, so I ain't gonna even ask how much! I'm going to talk to my Dealer today and ask if they can get plastics. And that reminds me, where'd you source your black shrouds? The Dude Abides!
Click to expand...
You are a true adventure rider! Please show us the repairs when you are done....no matter how they look. The black plastic came directly from Husky and are for the Strada. They come without the decals which is fine for me. Ken liked the look without the decals and we pulled his off with a heat gun while he was here. Cost should be around $120 for the set, but your dealer may cut you a better deal. I may have to go in early tonight and pull out a movie!
 
Here's my JB Weld Bodge Job so far: I'll be putting her clothes back on tonight and see what the strength is like on my next ride...

Some of the Broken Bits & my license plate shrinkage. The red reflector already had holes drilled-so the Enduro Engineering plate mounted right up
JB2.JPGJB1.JPGJB3.JPG
 
The main radiator mounts were broken as well as the shroud mounts on top. My last JB session was on the frame mounts. I just used 550 chord to hold the radiator in place while the JB dries.
JB5.JPG
On the bright side, this beauty showed up from Down Unda'
JB4.JPG JB6.JPG
 
Looks great! I have never used JB weld on plastic. It looks like it should hold up nicely. Let us know how the test run goes. You went from "crash test dummy" to "lab rat".:D
 
The trick is keeping stuff firmly in place long enough to set. Seems like you done a stout job by all impressions! Maybe you could tell us how you like that B+B Bashplate once you've fitted it and bashed it round a bit!
 
I put the bike back together last night and the Radiator is holding well. But, that doesn't mean I trust it! I'll take the bike out and find some whoops to strength test the cold welds. I'm still going to figure out a better way to hold the Rad to the upper mounts. I also put the B&B on last night. What a sweet bash plate! I'll post pics in the Skid Plate options thread, but here's the bike back together. Cheers!
photo 4.JPG
 
Now that SW Motech have released some pictures of their Terra Accessories, it looks like their crash bars are designed to be fitted with a bash plate in place using both of the engine bolts on the frame. (or at least this is my interpretation of the images and their installation instruction diagrams)

SW Motech crash bars
http://shop.sw-motech.com/cosmoshop/pix/a/n/sbl_03_319_10000__b1360666928-3167.jpg

SW motech crash bars installation
http://shop.sw-motech.com/cosmoshop/artikelpdf/sbl_03_319_10000_b.pdf

SW motech bash plate installation
http://shop.sw-motech.com/cosmoshop/artikelpdf/mss_03_325_10000_b.pdf

These look like they should go straight on with the B&B Bashplate
 
nev.. said:
Now that SW Motech have released some pictures of their Terra Accessories, it looks like their crash bars are designed to be fitted with a bash plate in place using both of the engine bolts on the frame. (or at least this is my interpretation of the images and their installation instruction diagrams)

SW Motech crash bars
http://shop.sw-motech.com/cosmoshop/pix/a/n/sbl_03_319_10000__b1360666928-3167.jpg

SW motech crash bars installation
http://shop.sw-motech.com/cosmoshop/artikelpdf/sbl_03_319_10000_b.pdf

SW motech bash plate installation
http://shop.sw-motech.com/cosmoshop/artikelpdf/mss_03_325_10000_b.pdf

These look like they should go straight on with the B&B Bashplate
Click to expand...

That's what it looked like to me too nev.. I was excited to see they didn't use both engine mounts so that we could use other plates etc. The upper of the two bolts may be an issue for spacing, but we can probably work with it. I have my request in at SW Motech, but I think it will be awhile before we get them. They look perfect for my needs.
 
HARDER1 said:
That's what it looked like to me too nev.. I was excited to see they didn't use both engine mounts so that we could use other plates etc. The upper of the two bolts may be an issue for spacing, but we can probably work with it.
Click to expand...

If I'm reading those fitting diagrams correctly, there are 5mm spacers on both sides where it mounts to the upper bolt, which I presume would be omitted if the Sw motech bashplate was fitted. Looking at their bashplate instructions, it's design and fitting looks very close to the design of the B&B, so I think there would be no clearance issues, and possibly the only adjustment I see might be necessary might be the size of the spacer used if their upper bash plate mount thickness was significantly different.

I've just emailed the Australia SW Motech importer for any info they have on price/availability here.
 
HARDER1 said:
I put the bike back together last night and the Radiator is holding well. But, that doesn't mean I trust it! I'll take the bike out and find some whoops to strength test the cold welds. I'm still going to figure out a better way to hold the Rad to the upper mounts. I also put the B&B on last night. What a sweet bash plate! I'll post pics in the Skid Plate options thread, but here's the bike back together. Cheers!
View attachment 23250
Click to expand...
Hey harder1, I am pretty sure that that rad is the same as on the F800GS and the F800ST. Several on ebay, take a look and compare since you had yours in hand, you would be the better judge. Would be good to know which may fit for the "interchange ' list. Good luck with the repairs.
 
Bring some zip ties. Been using JB type stuff for years and always found it useful for getting home or saving a ride but not long term solutions. My opinion only.
 
Motosportz said:
Bring some zip ties. Been using JB type stuff for years and always found it useful for getting home or saving a ride but not long term solutions. My opinion only.
Click to expand...

I agree with you Kelly. Operation zip tie is in effect for backup. I drilled two holes on the plastic tab in the center of the upper plastic frame. There are holes beside the upper brackets and I made a zip tie loop on each side. That should keep things in place and on the fram post. For now...
 
The JB has been holding fine on some rides, but I backed them up with zip ties on each side. 100% not sexy, but it works fine and is solid. The lower frame post carries the weight in the up and down loads. It's the side shots from tip overs and falls that will pop things loose. SW Motech crashbars are next. This is good enough for the girls I date :cool:
;)photo.JPG
 
HARDER1 said:
The JB has been holding fine on some rides, but I backed them up with zip ties on each side. 100% not sexy, but it works fine and is solid. The lower frame post carries the weight in the up and down loads. It's the side shots from tip overs and falls that will pop things loose. SW Motech crashbars are next. This is good enough for the girls I date :cool:
;)View attachment 23709
Click to expand...
That's good news! Did you ever price the radiator?
 
Nice job getting her back together. I took a slightly different rout on the radiator mount (I also believe the F800 rads are the same but the mounts riveted to them are dif). I have a good friend in the HVAC business and he bent some aluminum channels which I riveted it the top and bottom of the radiator. I also riveted flat braces between the top and bottom. My first design mounting tabs did not work so I took some of the scrap aluminum and made the brackets pictured here. image.jpg image.jpg.

I talked him out of some expended metal and made a guard which I attached to the front support straps.image.jpg
 
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