The Honda CX500 custom side covers…

The Honda CX500 custom side covers take shape

The Honda CX500 custom side covers take shape

It’s been a while since we updated the Honda CX500 Scrambler build.  We are finished with the build, so stay tuned for updates which should be coming fast a furious.  There will be some twists and turns coming soon.  This post documents the fabrication of the Honda CX500 custom side covers…

Honda CX500 custom side covers

Honda CX500 custom side covers cut and trimmed...

Honda CX500 custom side covers cut and trimmed…

The first photo shows the template created to cut the perforated steel.  Once cut, this stuff can be nasty to work with, so be sure to wear gloves!  A basic template was designed on cardboard (cardboard engineering to the rescue once again!), and then traced onto the steel for cutting.  An electric sheer was used to make the basic cuts, followed by a bench-mounted sheer for final trimming.

The cuts leave a dangerous sharp edge, so we decided to wrap the entire perimeter in body panel trim.  This stuff is typically used for tanks and car doors etc, anything with longer, sweeping turns.  But with careful cuts here and there, you can get it to wrap around fairly complex turns.  Once you have the shape you want, a little heat activates the adhesive that is inside the trim.  Keeps it secure, but further heating allows you to move it around to fine tune the application.

Honda CX500 custom side covers on the bike...

Honda CX500 custom side covers on the bike…

Above is a shot of the Honda CX500 custom side cover on the bike.  This was before the trim was installed, just to check that fitment was working.  You can see the cut at the front is to leave room for the pods to breath and also allow access for removal.

Not sure that we could ever make the list, but check out Bike Exif’s top 5 custom CX500’s

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