Mounting the Rear Markers

I used a piece of 1" x 1/8" flat bar to make a bracket for the rear markers and tacked it to the underside of the tray.  I rounded off the corners to follow the shape of the marker mounts.  The wires run through a rubber grommet in the tray and up under the battery box.

"Arrow Deco Style" marker lights from DCC.

The Battery Box

I knew right away that the battery tray I got from BCR was not what I had in mind. I may try and use it on a future project but for this bike it wasn't going to cut it.  I also discovered that it didn't have the necessary mounting brackets for the various parts that mount to the stock battery box.

I fabricated my batter box out of 14 gauge sheet metal and used 1" x 1/8" flat bar for the mounting points.  I thought I had taken some pictures of the parts while I was building it but it turns out I didn't.  I used some thinner (16 gauge) sheet metal to replicate the stock mounting brackets for the starter switch and rectifier.

The battery box with mounting brackets.

I was going to mount the regulator on the back of the battery box but there wasn't enough clearance for the taillight housing so I welded a piece of 1/4" flat bar to the tray and drilled and tapped holes in it so the regulator could be bolted down.

The battery box with the starter switch, rectifier, and my "battery."

Welding the Tail Hoop

I haven't had much time to work on the bike and I have even less time to spend blogging.  Here are some pics of the tail section.

I cut the "tray" out of 14 gauge steel.

Holes were drilled in the frame and hoop so they could be plug welded.

Clamped and ready for welding.

I'm slowly getting more comfortable with welding.

After grinding down the welds I noticed a few spots that I'll need
to go back and will with weld.

I gave the tail a quick coat of matte black to make it easier to spot the
little imperfections that I'll need to fill in.  Overall it came out pretty clean