How to brace rad guards?

d2w

d2w

New member
All, I'm considering "beefing up" the mounting of my BulletProofDesign rad guards. I'd like to add a gussett/brace to the frame (or head :eek:) to help transfer the energy of a frontal impact. I seem to recall that some of you have engineered such a system (but perhaps for other brands of rad guards). If so, to where did you mount your braces?

Would it be safe to drill and tap the frame to recieve an (M8?) bolt?

What about welding an (M8?) nut onto the frame?

Can you tell the bike's Winterized in the garage, and I'm starting to get cabin fever? :(

Any suggestions or pictures would be great!

Thanks.

Dale
 
This is what I did to a set of Flatlands to fit my '07:

http://www.gasgasrider.org/gallery/data//528/thumbs/Rad_Guard_Mount.JPG

The Flatlands come with a rear mount, I just needed to cut it and move it back for better clearance and strength. For the Bulletproof guards you can use round stock and add a side bracket. Maybe the LTR GP brace would work, with some washers to adjust spacing. It would save some fab work for sure.

The headstays are easy, dont mess with the frame.
 
I had the Flatlands on my '01 XC300. The Flatlands and the radiators crumple easy on side hits.

The key to side load strength is triangulation. I suggest you make some thing similar to the CRD rad braces with dual GP style braces for solid protection. The CRD brace clamps to frame with no fasteners through the frame on the left side. The right side brace mounts to the frame at the ignition coil mounting fastener.

Here are images of modified CRD rad braces with 2 GP style radiator braces on my '06 EC300. These have stood the test of multiple crashes for 21 months.
 

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The Flatland brackets are offset to the front to allow the bolt to fit. You could use some bar stock with angle bends on the ends and new head stays for something like the CRD mount. I did mine like I did so I could ride ASAP. So far it has worked excellent. The Bulletproof guards should be very strong in side loading, but aren't the rad sides mostly exposed? They seem more like a big "cap" for the front of the rad. You can't see in that pic, but the sides of my guards have been beefed up with another 2mm aluminum plate thats bolted to upper and lower GP braces. If you make your own head stays you can put the mount point as far back and high to center as possible, you just have to clear the plug and tank.
 
Thats some nice work there bergerhag! Makes me look like a hack.

If you can on the FSE, add a rear mount.
 
My flatland style with the ltr rods are very beefy. They were on my 99 for 6 years and have been on the 02 for a couple now as well. Countless crashes with little to no deformation. I think SpeedyManiac posted that he runs supports back to the perimeter frame which would make them extra strong. I would love to see some pics.

Paul B
 
Glenn and all,

Thanks for the ideas and the pics.

Glenn, are the three-point headstays a custom item, or are they part of the Flatland kit? I assume that the brace (from the rad side to the headstay) is a Flatland item (since it has the sticker).

I currently run with Bulletproof guards and my own version of the LTR reinforcing rods. I think that next simplest step would be to use some plate aluminum (with an added bend on the edge for strength) to protect the side of the rads from a side impact. I could simply bolt the plates to the sides of the rad guards. Hopefully the energy of a side impact would be transfered through the rods and guards to the frame.

Yes, the next step would be to go with a headstay pointing point.

Thanks.

Dale
 
The headstay is my own design. Very easy. I made a few cardboard models to get the best position with the cut and relocated Flatland bracket.

Sorry about the thumbnail, just realized that. Gallery photo tells all.
 
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