Front mudguards (general question)

[ukjules]

I need a front mudguard for my GS550et (1980)

Its for the bike in my picture and is plastic / red. It looks ok but i smashed it on a journey this summer.
I cant seem to find new plastic ones (you could back in the 90's)

Also the replica chrome ones i can get and might do so.
The thing is you need to drill the holes oneself where they attach to the forks. (4 bolts)

Q) How do you drill the 4 holes to attach to the forks ?How do you mark them exactly ?

[fastbysuzuki]

I need a front mudguard for my GS550et

Q) How do you drill the 4 holes to attach to the forks ?How do you mark them exactly ?

Does your mudguard have a steel re-enforcing bracket where it bolts to the forks if so can you not remove it from the old mudguard and press it inside the new one and Mark through.

another way would be to get some grub screws from a engineers store the same diameter as the mudguard fasteners screw them in the forks backwards so the hardened tip is pointing outwards then you would need a couple of clamps lightly position the mudguard into the required position and tighten the clamps onto the grub screws and release this will leave you with the marks to drill.

[ukjules]

The mudguards are off eBay. No pre drill holes.
They look good though for £55.
But I can't do the holes .
Even with your explanation I cannot see how I can make an exact job.
They are a tight enough fit anyway .
I can do a "ok" job and might get the holes within a few mm.

I want a red plastic one really.
Back in the day you could get them but not now.

[steveb922]

I have some aftermarket mudguards (old and rusty) - I could take some measurements if required. Do you want to post a link to the one you are considering?

Also, weren't the later 550s (as in EX or EZ) fitted with plastic mudguards?

[ukjules]

I am away so can't download and post pics.
Mine is a 1980 et, think standard was chrome.

Chrome will do and I'll strip and polish the forks back to ally
From the black paint on now.
I coukd position the new one now prob but I can't then mark the holes.

Basically what I can buy is a chrome new one that needs the holes drilling.
Otherwise it us fine. Sort of a pattern one that fits many bikes
as you need to drill own holes.

If you eBay gs550 et front mudguard you will see it.
Am also looking for a plastic one but they don't make em now.

[ukjules]

http://www.ebay.co.uk/itm/182191128999

[steveb922]

The standard for an ET - discontinued, but Francos Motorcycles had one recently for about £150.



If you decide to get one of the generic ones from E-bay, I can provide measurements. And the reason I suggested the later models is because they had plastic mudguards. If you could source one, it would be a direct fit.

[ukjules]

Many thanks.
The url I sent is so so similar to standard hence me wanting it
£55 too.

Just needs some modification.
It's identical I think to the one on my gsx 250.

As I can't find or buy a under seat helmet spring , my other post
I think I'll try this front mudguard project.

I'm gone order it and also try and fix my red plastic one
with filler and fiber glass.

Thanks for offer. I'll be in touch ... Jules

[fastbysuzuki]

http://www.cmsnl.com/suzuki-gs550e-1981-x-e01-e02-e04-e18-e21-e22-e24-e25-e26-e30-e34_model13480/53110-34510-13l-fenderfront_531103451000j/#.WDQFn7TfWhA

[hillsy]

If you get 2 pieces of rope (about 1/2 inch thick) and tape these to the top of your tyre (along the length, about 2 inches apart) then you can lay the new mudguard on top of this and mark out the mounting holes. The rope gives you the tyre clearance you need.

[ukjules]

I note the red mudguard on cmsl !!! That would/might do it but also break my bank....
(As always I try to do things cheaper....)

The rope method gets the height but how do i get the hole locations ?
Impossible access and the holes become invisible when the mudguard is on ?
I am convinced if i took the wheel off after marking i could get the approx hole locations.

I dont want approximate though ? I am missing an engineering method here somewhere.

[Grimly]

As mentioned above, the plastic factory guards originally had an internal brace, that is a perfect template for your holes. Fitting a plastic guard without a brace, internal or external, is not recommended.

[ukjules]

Good point !
Madly I have done just that.

Anyway the mudguard i am going to get is this - attached. You can see the holes will need to be drilled.
How I mark the holes still eludes me.
(I might be able to use plastic current one as a template. (no internal brace mind)

I know I can fit in place and then mark round the outside and from that measure guestimate BUT

the question has now got to be answered.
If we were NASA scientists and had to mark the holes how would it be done ?

gs550 pattern mudguard.jpg

[steveb922]

Take measurements from the one I have hanging up in my shed - it's exactly the same mudguard, and was previously fitted to a 550ET.

[steveb922]

Ok, from the bottom edge of the mounting bracket area, mark a parallel line at 38mm up. Then measure the distance between the mounting thread centres - approx 62mm. Make two marks on the previous line to match that, equidistant from the outer edges. These will be approx 18mm in from the edges.

Double check the measurements before you drill anything. If you drill one side, then mount the mudguard, you can adjust the other side if necessary. If you find you are slightly out, and have to re-drill, use a penny washer under a lock washer to secure those areas.