DIY Under Tail cover for ZX6R-C1 - ZX6R Forum
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post #1 of 20 Old 04-17-2013, 08:33 PM Thread Starter
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DIY Under Tail cover for ZX6R-C1

Hey guys, just picked up a '06 636 from my buddy. So after frustrating searches and e-mails sent to multiple companies, I have decided to start on a project over a couple weekends. I'm putting a Werkes lateral exhaust on my 636 since the undertail exhaust was already removed. There is the UGLY void under the back seat and I want it to be pretty.

I'm going to be doing a step by step DIY fab of a cover with pics for my '06 since HBR stopped making the kit, and people who want to sell their used one for outrageous prices. So for those of you looking for a solution, I'm going to be making one for you to follow.

The plan is to measure out with construction paper, then buy some foam board and make a mold to cover in fiberglass, sand and paint. I know it's easier said than done, but I've worked with fiberglass and it's fairly easy. Priced out the stuff and it should be a $60-80 solution. Hopefully when this is all done the mods can make it into a sticky, but not until my project is complete.



Removed the seat, side fairings, and rear seat to get the tail off.



Measured where I wanted the cover to end on both sides before I removed the tail.




Traced out a basic template to work with.



Added about 1/8" all the way around the sides, and measured the tip that covers part of the rear tail light. Have a basic mold to fiber over.



Basic layout



2 layers of mat, 1 layer of cloth



Fits the tail nicely

Counting Cost: Crafting materials were about $8, fiber mat/cloth, resin, bondo clay and paint came to $75 Total: $83
Counting Time: ~4 hours craft, ~20 hours of dry time

More to come....
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Last edited by Sofireguy; 04-27-2013 at 07:30 PM.
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post #2 of 20 Old 05-02-2013, 04:45 AM
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How much to make me one? Pm me
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post #3 of 20 Old 05-02-2013, 04:57 AM
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Excellent broda ! Im getting the same competition werkes side exhaust i have an undertail two brothers slip on now but would like to get the werkes just to have two options for sound, i know im gonna have to trim my lower fairing a bit but thats ok, anyway nice write up ! Is werkes loud ??

2006 zx6r kawasaki
-LEDGLOW lights green
-competition werkes side exhaust slip on
-afternarket windscreen with custom decal
-graffiti custom lettering decals . Custom license bracket
-ebay levers-spools-painted bar ends-frame sliders
-ebay tank pad and gas door cover
-custom wheel stripes
-integrated tail lights -aftermarket front signals
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post #4 of 20 Old 05-02-2013, 03:43 PM
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Originally Posted by rrodney24 View Post
How much to make me one? Pm me
I was thinking the same thing!!.How much he would charge just to make me one since we have the same exact bike?
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post #5 of 20 Old 05-02-2013, 04:45 PM
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this is pretty easy to make, its about $20-30 for the fiberglass and resin at homedepot. just make your own template and start to fiberglass. only thing that would concern me with the undertail is the exhaust heat and the fiberglass.
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post #6 of 20 Old 05-03-2013, 03:12 PM
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Quote:
Originally Posted by AgentOrange View Post
this is pretty easy to make, its about $20-30 for the fiberglass and resin at homedepot. just make your own template and start to fiberglass. only thing that would concern me with the undertail is the exhaust heat and the fiberglass.
He is going to use a side exhaust,so no problem with heat.
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post #7 of 20 Old 05-08-2013, 02:49 PM
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I'm considering the Werkes exhaust for my 05, could you do some kind of write up on it? Maybe a sound clip? I can't find anything on the web about it for the 05-06 636.
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post #8 of 20 Old 05-09-2013, 07:11 AM Thread Starter
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Quote:
Originally Posted by bgballin26 View Post
I'm considering the Werkes exhaust for my 05, could you do some kind of write up on it? Maybe a sound clip? I can't find anything on the web about it for the 05-06 636.
Quote:
Originally Posted by renzovc16 View Post
Is werkes loud ??

Yea I can put that in another post. I actually got the Werkes mounted, and it sounds great. With the baffle on, its still loud enough for me, but I like the deep throaty pur it gives off. When you open it up, it screams.

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Originally Posted by rrodney24 View Post
How much to make me one? Pm me
Didn't plan on making a ton of these, but I also ordered a Hotbodies 06-07 ZX10R plastic undertail to see how easy it would be to just mod one of those with a dremel and a heat gun for an easier method to crafting a cover.

I'll post that here as well for a comparison between the 2 with cost and time.
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post #9 of 20 Old 05-09-2013, 07:53 AM Thread Starter
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Quote:
Originally Posted by AgentOrange View Post
this is pretty easy to make, its about $20-30 for the fiberglass and resin at homedepot. just make your own template and start to fiberglass. only thing that would concern me with the undertail is the exhaust heat and the fiberglass.
Also, generally unless you are working with above boiling temp with fiberglass, you don't have much to worry about, as it is a thermoset polymer rather than a thermoplastic. I actually still need to bend the tip of my cover for the light piece, and can't just use a heat gun, so I have to make a few cuts and re-set it with more resin and glass.

Granted there is a tempurature for every material where there is a melting and destruction point, but even with undertail exhaust, it's far enough away from the headers to not effect a fiberglass cover.
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post #10 of 20 Old 05-11-2013, 08:19 AM
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Quote:
Originally Posted by bgballin26 View Post
I'm considering the Werkes exhaust for my 05, could you do some kind of write up on it? Maybe a sound clip? I can't find anything on the web about it for the 05-06 636.
I currently have the Werkes Comp side mount now for almost a month and let me be the first to tell you.... It rocks! Sounds very nice and looks awesome. You'll be very happy.
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post #11 of 20 Old 05-11-2013, 12:36 PM
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"but I also ordered a Hotbodies 06-07 ZX10R plastic undertail to see how easy it would be to just mod one of those with a dremel and a heat gun for an easier method to crafting a cover.

I'll post that here as well for a comparison between the 2 with cost and time.
Like"

Very interested in seeing how this works out. The only thing i don't like about the werkes is trimming the lower fairing, and do you leave the black plastic piece that covers the mid pipe?
DoeMai619 do you have any sound clips or pictures of your install?
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post #12 of 20 Old 05-13-2013, 08:53 AM
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Werkes Comp GP style side mount

As promised I snapped a few shots of my Werkes side mount hope yall like it!

DIY Under Tail cover for ZX6R-C1-werkes-1.jpg

DIY Under Tail cover for ZX6R-C1-werkes-2.jpg

DIY Under Tail cover for ZX6R-C1-werkes-3.jpg

DIY Under Tail cover for ZX6R-C1-werkes-4.jpg

DIY Under Tail cover for ZX6R-C1-werkes-5.jpg
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post #13 of 20 Old 05-13-2013, 08:57 AM
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I didn't remove the plastic for the mid pipe. I didn't like the space it left when it was removed so I left it alone. Cutting or trimming the lower fairing to accommodate for the side mount was no biggy. I just picked up my in laws dremmel and vroooom! Im not the best but hey it Werkes for me!
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post #14 of 20 Old 05-13-2013, 03:14 PM
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Thanks for the pics, it looks awesome, i'm interested to see if the 06-07 undertail fairing cover is wide enough to make it fit. Are you running the Insert in the exhaust? Did you have to get a custom tune?
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post #15 of 20 Old 05-13-2013, 04:40 PM
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No insert. I wanted people to hear me when they can't see me. Personal safety reasons. About tuning I never did it and maybe i'll consider it in the far future.

How far along before you think you'll find out about the undertail?
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