Anyone fabricated their own covers instead of OEM plastics/fiberglass for BDM?

Energy One
Beach_Traveler

Beach_Traveler

Member
Has anyone had success with paying to fabricate your own parts? I was even thinking of chroming some parts instead of replacing with fiberglass or plastics. Any thoughts or lessons learned?

I have a 2005 Pitbull. Missing one (right side) cover, just beneath the seat. It flew off somewhere on the I-8 FWY. I've removed the left side as it was not even attached anymore. The tank cover is zip tied and used self-adhesive velcro to keep it in place. I am working on a better mounting set up. Thinking of hitting up a fence installer. They bend metal and I figured they could be used for an improved mount/bracket.

The manufacturer said he just started making some for my frame and year $399. I'd still have to pay for paint. Quite pricey. I live in San Diego, California. I've hit up some of my friends that like to design and tinker... I have a friend willing to try his new 3D printer, as long as the pieces are within the right size perimeters.

BDM1.jpg2005 Big Dog Pitbull.jpg
 
mleach72

mleach72

Well-Known Member
Beach_Traveler said:
Has anyone had success with paying to fabricate your own parts? I was even thinking of chroming some parts instead of replacing with fiberglass or plastics. Any thoughts or lessons learned?

I have a 2005 Pitbull. Missing one (right side) cover, just beneath the seat. It flew off somewhere on the I-8 FWY. I've removed the left side as it was not even attached anymore. The tank cover is zip tied and used self-adhesive velcro to keep it in place. I am working on a better mounting set up. Thinking of hitting up a fence installer. They bend metal and I figured they could be used for an improved mount/bracket.

The manufacturer said he just started making some for my frame and year $399. I'd still have to pay for paint. Quite pricey. I live in San Diego, California. I've hit up some of my friends that like to design and tinker... I have a friend willing to try his new 3D printer, as long as the pieces are within the right size perimeters.

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Hi Mike! I also have a 2005 Pitbull. The problems you are having are pretty common. The tabs on the side covers broke very easy, especially on the rigids. BDM made a reinforcement kit that I purchased from the dealer. It had 2 heavy plastic inner covers, and the kit came with 2 raw outer covers. If your orginal covers were still in good shape you could use them so you don't have to repaint. You just had to remove any remaining tabs that weren't broken, and attach them with some form of adhesive. I still have the 2 raw covers, if you want them, but I don't how you would mount them without the inner covers. They are the same as the original covers, but the tabs have been removed. I don't know if the reinforcement kit is still available from anyone or not.

The dash had problems too. I noticed my dash started getting loose, so I took it off to see what the problem was. The plastic brackets were starting to crack. I reinforced everything with a heavy layer of JB Weld, and it seems to be holding for the last 10 years. If your brackets are completely broken off, the velcro might be your only option.
 
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