Well, I really did it today. I didn't quite make it up one of those STEEP hills, and things got ugly in a hurry. I came out just fine, but my DS didn't. It took one really hard upside-down hit on the front end that I saw. Do any of you guys have a front bumper or yellow front plastic? Luckily I didn't bend any a-arms, rims, or anything behind the gas tank.

What's the right amount to extend a steering stem? Mine is bent pretty bad, so I'm going to go ahead and extend it when I replace the tube. I don't even want to know what a new one costs.

Speaking of the don't-want-to-know-what-it-costs category, I also got a hole in my oil tank. Anyone ever welded one up? Can it be done? What's the right way to do it?

Do any of you guys have experience with Trail Tech lights? How durable are they? I'm thinking about building a bracket to hold three of those lights in the stock space. Most of my original light bracket is destroyed, and I could never keep those tabs on the light from breaking anyway.

 

sorry, I'm no help for parts.

there are a few choices for extended steering stems - Roll Design, TBR I think, and maybe Diamond G - they used to make them but not sure if they still do. They all run around $300 I think, with the nice anti-vibe bar mounts that are really sweet. if you're just replacing your tube and plan to extend it yourself rather than buy a whole aftermarket one, an extra 5/8" minimum is required for aftermarket bars to clear tank.

you can weld the oil tank - it doesn't have any actual pressure in it. its really thin - it'll blow through easy so don't attempt if you're not experienced with sheet metal welding. tig would be the prefered welder of choice.

those light tabs can be puttied back on. use epoxy putty and build up a big area all around the joint and it'll be stronger than it was new. mine are done this way. I mean build the putty up like 1/4" thick all the way around, but file/groove up the plastic first for a good bond. it works great, and is unseen.
the new '04 models have a new light fixture that mounts diferently, has twin beams, fits right inside the same front plastic. I want it, might be an alternative for you too. look at them at the bomb site.

 

JB weld will work good on your tabs too [img]i/expressions/face-icon-small-smile.gif[/img]

 

I've got a stock oil tank.
PM me for details.
-T

 

Theres a set of frond and rear yellow plastics on ebay right now. I did just what you have done a month or so ago. My rear axle is still bent not bad enought to effect performance though. Its pretty easy to fix your headlight. The fiberglass and epoxy thing works real well. Thats what I did. Good things you didnt bend your a arms or anything else. Best bet for parts are the dealer or ebay. Good luck. Sorry only thing I have to offer is labor or advice.

 

The oil tank can be brased and the repair will last for ever. All you need is a oxy/acetylene torch and a some brasing rod. Know anybody in high school metal shop?
I caution against any kind of electric welding,mig, tig, or arc, unless the welder has plenty of experience in welding thin gauge sheet metal. A little hole can turn into a huge hole in a milisecond if not done right.
Also, Oil is combustable so I suggest that you clean out your tank with a nonflamable solvent before welding on it.
My .02

 

I order my plastic fromSan Diego motorsport warehouse,www.sdmsw.com . They are inexpensive and ship it to your house. They seemed really friendly and helpful. My new front facia cost me I believe $98 (no stickers) and new rear fenders were around $89 (with stickers) plus shipping which was around $25. My friend flipped one of my ds's [img]i/expressions/face-icon-small-blush.gif[/img] and I thought my oil tank was punctured too but it was only the oil return line. Don't know if it helps but ????????? [img]i/expressions/face-icon-small-wink.gif[/img]