Late model shrouds on an 03+ Hybrid

[Biggles]

Thought I'd do a step by step of how I fitted the 06-08 450f shoruds to my 04 Hybrid.
I searched a few forums and the best starting point is the shroud. 06-08 shrouds nearly line up with the tank bolts and is the easiest to make fit. Other models require adaptors to be machined for the top tank mount and as such it was put in the too hard basket....

The blank canvas

06-08 shroud - I scored a NOS set for $60NZD delivered

[Biggles]

Step 1

I had a metal lock nut welded to the standard radiator support bracket to line up with the shroud hole and made a small aluminium bracket for the bottom of the radiator


Step 2

Elongate the top tank mount hole (had just drilled but not finished with the round file)

[Biggles]

Step 3

Need to trim a small section off the bottom of each radiator flute



(note - each side is slightlt different so measure twice, cut once )

Step 4

You need to trim the inside bottom lip off the shroud where it rests against the tank so the shroud sits a bit more flush


I trimmed the black marked area off....

[Biggles]

Step 5

Attach brackets



(yes I know the alu bracket could be a bit neater and intend to make some more shortly - this was a test run)

Step 6

Fit shroud



Please note - this is the way I went about fitting up the shroud and seemed easier than most who make a new rad support arm etc. The shroud tucks in nice and tight and looks like I was hoping. Other people may have different fittment methods but each shroud took an hour start to finish (except paint time, including weld time). Later model ones would be nice but from what I understand none of the holes line up. At least with these three (if you include the nut welded directly to the rad support arm) line up really close....

[Biggles]

The finished product

[Tedh98]

Nice write-up and pics.

I'm waiting for some 450F shrouds to show-up, should be here tomorrow. I was sent 250F shrouds by mistake and as you indicated, with the tank holes being off it would take the project to a new difficulty level. Not even sure how you'd get the upper tank hole to bolt up without sticking out.

[diymirage]

completly off topic but what in the world is going on with your garage floor ?
i mean, you can SEE it

i know i have a floor in my garage, i seen it when i moved in, but i havent seen it in years

[Biggles]

completly off topic but what in the world is going on with your garage floor ?
i mean, you can SEE it

i know i have a floor in my garage, i seen it when i moved in, but i havent seen it in years

Ha, the wife asks the same thing

[Tyl3r]

bike looks awesome man! and yea lol sweet garage too!

[Tedh98]

I finally got the shrouds on my hybrid. It took three tries on eBay to finally get 450F shrouds.



I liked your idea of welding the nut on the radiator braces, but that wasn't going to work in my case. So I made new braces out of 1/4 aluminum.



I also made these off-center washers to cover and clean-up the lower tank mounting hole.

[diymirage]

I also made these off-center washers to cover and clean-up the lower tank mounting hole.

not that i really like

[Biggles]

I also made these off-center washers to cover and clean-up the lower tank mounting hole.

[/quote]

Nice job, think I'll steal the off centre washer idea

Hopefully I get to ride mine this weekend.....

[Biggles]

I finally got the shrouds on my hybrid. It took three tries on eBay to finally get 450F shrouds.



I liked your idea of welding the nut on the radiator braces, but that wasn't going to work in my case. So I made new braces out of 1/4 aluminum.



I also made these off-center washers to cover and clean-up the lower tank mounting hole.

Hey Ted

As my hybrid is now in pieces again, am toying with the idea of grafting a complete 08 450f back end onto mine. Already started searching for an airbox, side covers etc so we will see where this ends