Well, I would'nt want to go touring, but.............

Foamsolutions on ebay provided a block of 45mm High Density Closed Cell Foam.

• Easy to work with. Treat it like a soft wood.
• Lightweight.
• Waterproof (not that it matters after its covered)
• Cheap - under £10 delivered, and enough for two seats)

However, I couldn't recommend it if you intend traveling for any distance. I'm sure I've sat on softer rock!

A couple of hours work, and the "cushion" (really?) is shaped and almost ready. I may rub down the side edges a bit more. I'll walk back into the garage in a couple of days and see what my first thought is. The main cut's were made with a jigsaw, smaller cut's a hacksaw and a sharp knife, and a sanding block finished it off. Every so easy.

Lunch break fabrication

The seat has a slight kick to clear the rear mudguard (it's taken longer to post this than achieve that) the rear mudguard is also now bolted in the correct hole, moving it back a bit, and a quick cardboard "template" of an idea for the side panel. I can get a "scoop" from ebay, in stainless or ABS plastic (there's also Carbon Fibre, but that's, well a bit excessive and expensive) and the rear frame brace welded in place (my welding is improving, just)

An ABS plastic "scoop" for a few pound's, covering two 38mm holes (to be cut) in the side panel. Form over function.

A spare few hours.................

Found some time to cut another seat pan. There's a 50mm wide plate now also welded across the frame seat rails, which I'm simply bolting the pan to (as well as the rear mudguard) which will get photo'd eventually.

Side Panel

I've been playing around with some sheet alloy, trying to knock up a decent side panel just to tidy up the newly fitted airbox.

My first effort was OK. I had thought about putting some sort of simple "scoop" or possibly a pair of mesh covered Stub Stacks. Then, stupidly, I attacked it with a 6mm drill. That didn't work.

I don't think I've managed to actually fabricate anything yet without at least two attempts. All a good learning curve

When it was on the bike, it just looked wrong.

For the second effort, the hole saw set reared it's head again. That didn't work either. Despite making another template, and cutting out the 38mm holes, which I thought was what I was after, in the metal it was too much.

So, plain it is, for now!

Mmm, what about a small NACA style duct feeding the airbox?

There's a 5mm gap between the airbox and the panel, which is enough space to draw in fresh air, but I still can't help thinking.....................................................................

I found a headlight that I like. It's affordable, made metal, and gives me the look I want. Supplied by a Plant Equipment supplier, as a replacement for a JCB Front Hoe Loader (other makes of loader are available) at under £25, it's a bargain. EBay again!

If anyone's after a "rugged" style front light, give me a shout and I'll send the seller's details.

A simple alloy bracket, bolted onto the lower fork brace will suffice, but it will need another pair of holes drilling next time the forks are stripped down.

I doubt that I'll get any tinkering time for the next two week's or so, but IF I do, now the oil tank is finalized, and I don't need to lift the seat easily to access it, I may have another look at an alloy seat base, bolted straight to the frame rails.