08 KLR Custom Headlight Guard/Grill Build

A couple years back my neighbor purchased a 08 KLR650 and wanted a custom Headlight guard so we decided to fabricate one up.

Here we are starting the fabrication. In this picture we are heating the ¼” round stock with a torch and bending it around different diameter pieces of pipe to obtain the correct radius.





Here we are sizing up the bottom piece of the frame for the correct angle before welding it in place.




Fitting up the mounts. Here they are in rough form and will be rounded and cleaned up before powder coating.




Fresh out of Powder coating and on the bike.




Closeup of the guard on the bike. The guard is mounted to the front fairing via rubber well nuts, the same kind that mount the windshield to the fairing. This provided a solid mount for the guard and makes the guard easily removable for maint.




Here you can see the curves in the guard. It flows with the lines of the fairing.




Front Shot




Hodakaguy

very impresive, you guys have some tallent. maybe you and big jer could get to gether, i would like to see what that would bring out !

tom did your garage get smaller? i see alot of open floor in those pictures.

craig2211 wrote:

tom did your garage get smaller? i see alot of open floor in those pictures.

Cleaned it a couple days ago...all good for a while again


Hodakaguy

Can you copy that and build another. I,ll trade you one of the kids or maybe cash. Looks almost like a factory aftermarket.

As always, nice work Hodakaguy.....