As I mentioned earlier, I recently fired up the RGV for the first time in a long time. Before starting the bike, I needed to re-fit the various electronic boxes to the wiring harness. Specifically the SAPC unit, and the CDI unit. The SAPC unit attaches to the sub-frame of the motorcycle, which meant I had to re-install that as well.
This was the first time I had installed these parts, since installing the rear shock absorber from the GSX-R 600. Unlike the standard RGV shock-absorber, the remote canister “piggy-backs” on the main body of the shock-absorber. Although it did not touch the SAPC unit, this canister was in close proximity to the expensive box of electronic trickery.
It was not hard to imagine that a minor tumble may have flexed the swing-arm sideways enough for the canister to collide and damage the SAPC unit. Whether or not this sort of incident could occur was irrelevant – I decided it was safest to avoid the problem altogether by relocating the unit.
I am definitely no expert when it comes to fabrication of parts, but I was enthused with the optimism gained by having the right parts and tools for the job. First effort was to make a cardboard mock-up of the tray. I decided not to allow too much depth in the tray, as experience has taught me that the rear wheel travels further than would otherwise seem likely. Careful measuring allowed for a neat fit between the rails of the sub-frame. Having gone through this process, my only recommendation is you take great care to “flex” your cardboard cut-out as little as possible when lowering in and out of position. Parts of the final design were influenced by the need to be able to manoeuvre the tray into position without bending it.
The rest of the build process was slow and methodical. I used 0.6mm galvanised steel sheet – as that is what I had available. After carefully measuring out the dimensions of the tray, a pair of tin-snips cut it to approximately the right shape, and then a bench grinder and hand-file finished off the shaping.
Folding the sheet was done by hand, holding the plate in the vice, with bits of timber to add support to either side of the fold line. Somehow, I managed to avoid any silly mistakes caused by folding the sheet the wrong way!
Another rectangular sheet was riveted to the tray, and folded in position to form the “back piece” of the tray. This then bolts to the sub-frame where the pillion seat brace is.
At this stage, I have yet to put bolts in to secure the SAPC and CDI boxes. Final placement of these parts is still to be determined. If there are any readers with an RGV, they may be wondering where I am planning on putting the battery. – On a standard bike, this tray sits where the battery recess was. Well, rest assured that I have not forgotten about it, but that is a story for another time.