Another part to my 2008 Triumph Bonneville that I have decided to modify after my accident is the front sprocket cover. In my case it is a black powder coated cast aluminum part from Triumph.
I have been collecting ideas of various designs and modifications I’ve seen posted online. I decided that I still wanted the protection of a full cover, but to add some personalized touches.
Based upon the Joker Machine headlight ears, I have been drilling holes in various parts of the bike (chain guard, shift lever). I decided upon this same basic direction for the sprocket cover as well.
First I laid out my design in pencil on the cover. After several layouts, I decided on 4 holes in a line across the centerline of the cover.
Next, I center punched each hole and drilled small pilot holes to guide me with the larger holes to follow.
After attempting to drill out a larger hole using my drill press, I decided that using a hand drill would be easier and safer, so I switched to clamping the cover in a vice and using the stepped bit in my Makita hand drill.
I used the stepped bit to also countersink the holes on the outside and inside.
I used a cut off tool and angle grinder with various metal cutting, sanding and polishing wheels to remove the inside aluminum bosses and clean up the holes.
I then used metal scotch pads to clean and smooth out the inside and outside, prepping the metal for painting.
You can see that I ended up drilling two smaller holes at the front and back and two larger holes in the middle. It just looked right to me.
March 8-9, 2014 Updates
This past weekend I started applying final coatings to the sprocket cover. I am using black Plasti Dip by Performix, which I purchased from Home Depot.