Smuggler part II

34 2005 FJR

1 Making a template

2-Covering with a release agent

3 Checking the fit 2013 FJR

4 Casting over the seat pan for the bottom

5 Fiber glassed, next is to bond the two

6 Bonded, cut access hole

7 Bondo for smooth surface

8 More bondo

10 Primer

9 Sanded smooth

11 Making the lid

12 Making the lid

13 Making the lid

14 Bondo and putty

15 Sanding

16 Left 2005 FJR - Right 2013 FJR

17 Finished

18 Completed

19 Note Givi Rack

20

21

22 Box won’t fit with stock FJR rack 2016

23 Modified to fit what th stock rack

24 Fiberglass

25 Fiberglass

26 Sanded ready for Bondo

27

28 Primer

29 Finished except for lid

30 Able to use old lid by trimming back

31

32

33