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From: sean_q_ on 28 Jun 2010 22:03
Hi, I'm a newbie with only moderate mechanical skills
and resources. I'm restoring a bent '05 Triumph Thruxton
and fixing up a '94 Magna V45 with a sidecar.

As usual, I need to modify some materials (rarely does
anything I have, buy or scrounge ever bolt right on
without some futzing and tweaking).

(1) I have a wraps-back-around-behind-the-signal-lights windshield
which I need to drill holes in and trim the bottom extensions
(which collide with the Magna's radiator). However I've found
windshield material to be very brittle when trying to cut it --
what's the best way to drill and saw through it? (And smooth
it afterwards, such as with a file etc?)

(2) I needed some hard-to-find headlight supports for the Thruxton
and finally found a pair of chromed muffler support brackets which
(almost) work. They're basically a long metal bar bent into an open
ring at one end which (with a slightly larger diameter) would fit
around my over-the-fork sleeves. An already existing hole
at the other end fits the headlight's mounting screws.
Near the ring there's another bend but at too large an angle.
So I need to expand the ring part and reduce the bend angle.
How do I go about this whilst leaving the chrome intact?
I may also have to drill holes through the straight parts.
Is this possible without causing the chrome to peel away?

(3) The Thruxton's gas tank has a dent as if the Jolly Green Giant
punched it. However the dent's contours are all smooth; ie no creases
or sharp bends. Some Google research found a clever gadget called
a Ding King designed to fix dents by pulling them out with a glued
suction cup. Has anyone here ever used one and is it worth trying
or am I likely to do more harm than good and would I be better
off taking it to a pro?

TIA for any help,
SQ
cc rec.motorcycles
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