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Did-it-Myself fiberglass numberplate

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heading to Durhamtown in a week or so for 3 days of riding and hated the idea of taking the bike up there with all the street lights on it. dont want to damage them and maybe the few pounds i shed by taking them off will make me trail riding superstar lol!

so i went to lowes and got a piece of 26ga. steel, 5 bucks, and made a template for what i guess i wanted it to look like.

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traced it onto the steel and cut it out with snips

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i left about a 1/4 inch to bend up to make forming the edges possible

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then i took a piece of flat stock and banged a little shape to it

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then i took some fiberglass mat my buddy left over here and some resin, cut out 4 layers and laid it all in the mold and got it wet out as best i could

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let it sit overnight(old resin took forever) trimmed the edges, then twisted on the mold until it popped out

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nice shape i guess...

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then i took off all the street stuff including the switch assy from the left side, bundled it up, then folding the headlight brackets in on the bundle

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drilled a hole, slapped some paint on it (screwed up have to redo that), found a 1 inch spacer and a longer screw for the bottom mount and i'll probly just use a zip tie through the center and tie it to the wire bundle behind it.

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sure it would be easy to buy something else, but this was minimal cost and kinda fun, i'd never molded anything before and i can see the potential for other parts with some better equipment (vacuum bag, etc...)

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I love the stuff that people do themselves. Anyone can buy something. How much weight do you think you saved by taking off the light assembly?

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I don't know, between the headlight, signals, tail light, blinkers, and tag bracket, maybe 7 pounds??? But its all weight where you dont want it so I guess any reduction is a plus. And, I plan on running the fan on a manual switch so not running the lights saves a little power for that too.

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I would remove the fan. the DRZ400E doesn't need it. I don't think my fan ever turned on so I took mine off. No problems ever. With no lights maybe try a Lithium ion battery. That will save you another 7lbs.

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yeah i need the fan, the group we ride with ranges in experience and gumption level so we inchworm through some of the trails. a buddys ktm450 went off like a pressure cooker a few times last trip, dont want that to be me lol!

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