GIVI TS836 passenger backrest for KAWASAKI VN900 Custom / Classic '06-14 with removable luggage rack

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GIVI Backrests / Accessories for panniers

GIVI Windshields

KAWASAKI accessories (original)

I would like to share my experience of creating a minimal tuning kit for long trips for the Kawasaki Vulcan VN900 Classic motorcycle - 2007. 1. Trunk with fastenings; 2. Passenger backrest; 3. Passenger platform footrests with fastenings.

This is how the bike was before my intervention, I really liked it, but it’s not suitable for long trips:

I have always been against additional attachments that change the appearance of the motorcycle and make it heavier, but after a trip with my wife to Altai in 2012, I had to reconsider my opinion. It’s okay to drive without a windshield and cut through the air to my satisfaction, but carrying serious weight in backpacks on my shoulders is too much, and on bumps my other half was always afraid to fly off the small passenger seat of the Vulcan. It was decided that there would be tuning, but what kind and from which manufacturer it was not clear... Finding tuning for this model on the Internet is not difficult, BUT the prices were high. Well, I didn’t want to give 40 thousand rubles. for the windshield, passenger footrests, trunk and passenger backrest, not to mention the mounting of the panniers and the panniers themselves. And then it dawned on me! I wanted to try to do some of the tuning myself, or almost myself, with the help of “moves” to factories for the production of metal structures. Having assessed my strengths, I abandoned the idea of ​​molding the windshield onto a matrix, which would also have to be sculpted in the garage; in short, it would have turned into an endless soap opera. Therefore, I ordered the windshield and mount from the store. It arrived very quickly, and from the quality I saw (glass made in the USA), I almost gave up the idea of ​​making the pieces of iron on my own. All fastenings, the general appearance of the glass, the edges of the glass, and the even shine of the plexiglass were at a high level. However, in the end I overcame my fear and started... The idea was this: I run to the stationery store, buy whatman paper, a pattern (when I asked about the pattern in an average stationery store, they looked at me with bulging eyes, like: Eeeee, what is this?), a metal ruler and that’s it. Yes, the kit, frankly speaking, is like a first-grader's))) Next... I draw sketches of the main side brackets, the passenger backrest, arrange the dimensions and run to the factory, my heels sparkling. It took a couple of weeks to make the scribbles, I was busy “drawing” after working with an important-looking designer)))) At the factory I asked to make “grubbyak” mounting brackets in order to understand whether my idea had a future. I immediately apologize for the quality of some of the photos, I never thought that I would have to publish them))) Two pieces of iron were cut out of sheet steel using a manual plasma cutter, holes were drilled, parts for the trunk were heated with gas and bent (I was not able to take part in this work). After cutting, the piece of iron looked unsightly, the edges were rough, but the holes “fit” perfectly, in a word, “test sample.” I installed the brackets on the motorcycle using a set of washers under each bolt, so as not to crush the plastic chrome trim on the rear fender. I measured the distance between the two brackets in the area of ​​the future trunk and the future backrest, got the width of the trunk, and the width of the backrest seats. Made adjustments to paper sketches:

I looked at what happened from the outside and realized that there would be no beautiful tuning, we need to go in a different direction. Namely, to make pieces of iron using CNC routers (programmable), for this you need: - to master the “drawing tool” on the computer; -find a CNC milling machine. I installed the program on my work and home computers, through trial and error (thanks to Google), I drew the first blanks, and began looking for a contractor with a CNC router…. None of my friends had what I needed, I thought everyone had them in their garage)). The same friend Konstantin, who made the first test samples, and also the director of the plant, recommended one place - a plant with metal laser cutting machines. I send sketches by email. form in two extensions, I receive the answer: Yes, we can fulfill your order! I am overwhelmed with emotions, the ice has broken. After that, I redrew and corrected my electronic scribbles many, many times. And at this time, winter began to lose ground, but my horse was not lying around! I pull myself together, make the last additions and send it to the factory... the guys ask me to deposit the money immediately according to the specifications set...... I wait a day, wait a second, a third, and on the fourth a letter arrives: “Your order is ready!” The blood is pounding in my temples, adrenaline is rushing through my head, and from the very early morning I have been rushing headlong towards the factory entrance at 08:30. I called and they brought out a bunch of records, things and trinkets wrapped in stretch film. I run through the melted snow, stumbling, to the car, open the trunk, put a translucent heavy package in there, tear the polyethylene with wild eyes... I exhale! At first glance, it’s almost exactly what I wanted!)))) Dance right next to the car! Oh, what a pity that I didn’t take intermediate photos ((The next day, having collected printed drawings and pieces of iron in a pile, I go to Konstantin’s factory for bending and welding of parts. The answer to me: Don’t worry, everything will be done!.. In business and worries Time flew, spring passed, summer came... The planned trip to Altai is approaching, but I have nothing ready, except laser blanks and a curved back! Thanks to reliable friends))) There are a couple of weeks left until the “X” day. I forgot to mention that during this time I bought stainless bolts and nuts, and made a back cushion based on the sketch (the work was done by the guys from a car repair shop that reupholsters car interiors). What to do? I go to the factory, change into work clothes, director Kostya follows my example and begins to sculpt: we bend the trunk, bend the passenger backrest, cook the platforms, put together the platform brackets - weld them. I’m leaving the factory with a bunch of semi-finished products... In my garage I’m putting the trunk back together in a heap, putting the trunk on, installing the brackets on them for the passenger footrests (I see that they stick out a lot to the side, I miscalculated a bit with the dimensions, I’m cutting it, I’m adjusting it again)... I exhale... Time is running out at this moment. I process all pieces of iron with an eccentric fine sander with P180 sandpaper (that’s a muddy grinder!):

Ideally, give it to chrome plating! Imagine I couldn’t find a single competent galvanizing operator in the city of Novosibirsk!!! How is it that it was necessary to destroy, plunder, and destroy an industrial city in a couple of decades? There are a few artisans left who, in light of strict legislation, are still chrome plating (due to the use of concentrated acids). According to the “plater specialists”, their chrome film will withstand 2-3 years in the open air under normal conditions, then it will begin to lag behind the metal surface. This is not acceptable to me. Chemical metallization was immediately rejected due to the low hardness of the coating, although the shine is absolutely mirror-like. Manufactured from polished stainless steel due to an expensive water jet cutting process. ... We're leaving soon, literally four days left. At this moment, there is no paintwork on the tuning, and there is no rubber base on the platforms. The simplest and fastest solution for coating is to put it in polymer, paint it metallic silver, and protect it with epoxy varnish on top. The footrest brackets are polymerized matte black. I gave it away... They call: - Everything is fine! I come, I’m dancing, it’s not good! Not good! The fact is that they applied the paint to a poorly or not at all prepared surface, and here and there you could see slight rust and fingerprints))) I realized - there’s nothing to catch here, there will be problems again, well, there’s very little left! I go to my friends at the service station to go to the paint shop, change clothes, matte the polymer coating, turn it on metallic silver, paint it, “fix it,” and leave it overnight. In the morning, at a construction store, I buy a regular rubber mat, pick up the painted parts, buy professional black polyurethane sealant for gluing car windows, and matte black paint in a can. At home, I cut out areas from the rug, glue in two layers of rubber, and leave it under pressure overnight! In the morning I very carefully trim the sealant around the edge. All. In the garage I paint the back black and put it together. In the evening, I secure a bag weighing 15 kg using zip ties on the trunk through a rubber gasket so as not to damage the varnish that has not yet completely dried during the trip): Winter photos (2013) during hibernation of the motorcycle:

Actually, this is the only photo taken on a phone (with a dirty “lens”), while stopping a motorcycle with a load (stopping near the village of Chemal for warming up):

Homemade tuning proved to be EXCELLENT! I survived the trip to Altai for the entire 2013 season.

BUT!

Already in the summer of 2013, I decided to make another set with a different, more harmonious and smooth trunk design, a different backrest, rigid pannier brackets, etc. The appetite, as they say, comes while driving.

New trunk:

Assembled frame for panniers with variable cross-section for rigidity:

This is what the frame will look like, all that remains is to weld the bushings for fastening to the motorcycle:

))))))) Good luck to all!

PS I express my deep gratitude to Konstantin!

To be continued)))

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Shaka everyone