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Discussion Starter #1
Now that I have your attention I thought I should place an warning to everyone interested in removing the rear grap handles. First you have to do a good fiberglass job. Next you have to sand down the entire tale. Finally get it painted. I realize this sounds easy and in fact it is the real bitch is putting the tail back on your bike. In order to have the a good strong fiberglass job to cover the holes you need to go from the inside of the tail and fill out.. this will prevent a bump on the outside of the tail. Now doing this you create a buildup of resin on the inside of the tail. When you attempt to put the tail back on the buildup will push the tail out and it won't fit. DO NOT sand the inside of the tail down to make it fit because you will be weakening the fiberglass job and eventually those hole will just collapse. INstead have yourself a good dremel tool and a lot of patience. You have to grind the hell out of the two mounting brackets on either side of the frame. These mounting brackets are steel and are what the handles use to screw into. You can't cut these brackets off because they provide support for the tail section. without them the tail will crush when you have someone on the back. so with a lot of patience grind a little then try it out.. grind some more.. then more.. It took me two hours of grinding to get it right. IF you are installing an undertail you have to have it perfect because if the tail is lifted the littlest bit you won't be able to overlay the bottom of the tail over the undertail. WHAT A BITCH!!! I am happy to report however it is gorgeous and done. Worth the effort but be full warned of what kind of a hassel it is.
 

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i dont think you are the first one try removing the bars and adding a undertail. but thanks for the WARNING on how hard it is...<img src=icon_smile_tongue.gif border=0 align=middle>

Vin:"I live my life a 1/4 mile at a time"
Arturo:Hahahahhaha...Why?
 

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i did all that to my tail wasn't hard at all, took me like an hour to cover the holes and fit it right, to me it was very easy to do, just had to make me a custom bracket to support the tail when i cut off the mounting brackets at the rear of the tail.

02 ZX6R (Kandy Tangerine)
 

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I've done this also. Actually, I cut off the mounting stubs where the rear handles mounted. It seems to me that the passenger seat provides its own support for the passenger. The cowling has nothing to do with it. It's sturdy enough as is, at least on my '99. As to filling the holes in the cowling...I used Plastifix. I reinforced it with fiberglass cloth on the inside. It seemed to come out well. I ended up cutting out the recessed mounting points on the cowling completely, that made it easier to fill in the holes. there are pictures available at...
http://fp3.antelecom.net/edurkee/images/motorcycle/12-5-02/modified_cowling_bracket.jpg
http://fp3.antelecom.net/edurkee/images/motorcycle/12-5-02/modified_cowling_bracket2.jpg
http://fp3.antelecom.net/edurkee/images/motorcycle/12-5-02/rear_cowling_installed.jpg

Diirk
'99 ZX6R
'02 Raptor
'01 Wolverine
'87 Radian
 

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Discussion Starter #5
I probably should have cut the damn support tabs but it looked like the tail would sag too low without them as support.. damn all that work for nothing. At least it came outnice.. I guess that is all that matters.. I'll be updating my winter porject link in the members profile section tonight..
 

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psyclone...
The benefit of doing it your way is that it's reversable. You can bolt a stock tail with handles back on whereas I cannot. I'd have to find a new tail bracket also. Not a big deal, but an issue none the less. It's also good that you shared your experiences, thanks. We have now provided three different ways for people to accomplish the task of removing their handles. Different strokes.....

Diirk
'99 ZX6R
'02 Raptor
'01 Wolverine
'87 Radian
 
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