I finished the final version of my Trailtech Vapor bracket. I was so pleased with the results I thought I'd post the info...

Materials:

1 1/2 inch aluminum angle iron

Tools:

Drill press
Jig saw / hack saw
Files
Bench grinder

Layout

Here's a rough stencil and my layout:



Drill 7/16" holes in the corners so you don't have two cuts meeting at 90 degrees. This makes for stronger corners.


Cut away to form the "straps" that will mount to the triple clamp:


The next steps are to make the bends. From the mounting plate you need to bend 3/8" to either side, 90 degrees to the strap, but angled out slightly from the mounting plate...maybe 5 degrees. I used a bench vise and a hammer. Crude but effective. Be careful not to bend to 90 degrees - it will crack the aluminum. The tabs that mount to the bike are bent 17 degrees to the straps at about a 95 degree angle.


Using the mounting plate supplied with the Vapor I laid out the mounting holes and the access hole the wires will pass through. Position the access hole 1/8" from the inside edge of the mounting plate for the best position.


Drill 7/16 holes at each corner of the access hole and 3/8" holes for the mounting screws (I clamped the Trailtech mounting plate to mine to use as a guide for the drill). Use a jigsaw to cut between the holes. File, grind, and then sand the edges - this must be smoooooooth. The grommets from the Trailtech mount should fit right in.



Mount the Vapor to the new bracket.



Here's the finished product installed:



The alignment came out perfectly. If I had it to do over again I might shorten the "straps" from 1 5/8" to 1 3/8".

 

Nice work.

 

Nice bit of "Heath Robinson."

 

Nice job on that. Only one question, what was the overall length of your angle iron?

Eric

 

Thanks.

Overall length was about 8 1/4": 3" center section, 2 x 1 5/8" legs, and 2 x 1" mounting tabs. I cut it a little long and ground the mounting tabs to fit after the bracket was completed.

I got the materials at the local Home Depot.

 

Cheers!

 

You should make a couple of those and sell them to the less talented people on here!

HEHE

 

I think Trailtech should give you a discount. I think you just sold one for them- looks like a great winter project for me!

 

Almost done doing the same. Just need that vapor and dashboard now for Christmas! Fingers crossed! I cant cut the holes until i have the bracket to trace and use as a guide.



Without your post I never would have considered a vapor. Thanks.

One question though, I see some guys with klrs not cutting into the tube for the temp guage but instead replacing the sensor inside of the bolt going into the radiator. If anyone knows if this is possible on the klx let me know.

 

Don't know how I missed this the first time. Nice Job!!