Some more progress despite the fact I have been also spending some time fault finding on the Sportster. I have made a prototype of the drivers side dash top, cowl - call it what you want. It's not bad for a first attempt although I will make it again now I have had some practice.
The flange that fits allong the dash hoop has to be stretched in order to get the shape. After evaluating various methods and tools I have used the old fashoined way of belting it with a hammer. Ok - so it's a special stretching hammer - but much cheaper than buying a proper shrinker/stretcher as used by some bodyshops. The marks left by the hammer will be hidden by the bonnet tape.
I have shaped the cowl in such a way that it covers the steering wheel thus hopefully preventing hands getting too cold. bending it in such a way means it is suprisingly strong. Even so I will be re-inforcing the edge with a U shapped ali trip strip.
Cheers, Robin
DSCF2028 by
Robin Martin, on Flickr
DSCF2026 by
Robin Martin, on Flickr