This week, we have completed our first mold for final manufacture. This piece is the feature for the tank, which also houses the fuel cap and acts as a top cover, sandwiching the tank cover between this and the aluminum fuel tank.
The image below shows some of the bosses previously machined in Nylon now fully molded and ready to go along with a split line to indicate where the piece needs to be cut back to when released form the mold.
With filler and resin curing, there has been plenty of time to make up all those pesky little brackets to hold coil packs, pressure switches, fluid pots etc and to start to get a grasp of the wiring loom and where it will all be located. Having made the frame narrower then standard and with a fuel tank which sits far lower, there was a certain amount of head scratching on how to get the main loom form the rear of the bike to the front, without it being too visible.
There may need to be a few extensions to certain wiring/connections, but these have all been noted and the position of the fuse boxes and components confirmed. Now its just a case of TIG welding these mounts into place when the frame is next stripped down.
The fuse box neatly mounts onto the rear subframe, positioned on the underside of the seat pan. We also have another black box of electrics mounted on the underside of the rear subframe tail piece along with this box of magic on top.
PS, If anyone can identify what this black box is/does, could they please inform me. There are two SV650's in the workshop, both with '99 registration, yet one has this and one doesn't.
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