March 21, 2012: It is a race to finish our streamliners by the Quail Vetter Fuel Challenge
On this side... Alan Smith streamlining his Ninja 250
Over here... Craig Vetter rebuilding his Helix Streamliner
Extending the streamlining

Because the Ninja rider uses footpegs, the sides of the streamlining can be extended to the rear more.

Jigs and fixtures

Making a plywood fixture that will help me to accurately make my streamliner nose.

Designing perfect parts

The fixture holds all the parts in correct position so I can mark and drill the holes.

Stock foot pegs

In regular riding position, Alan sits like this with his feet on the Ninja footpegs.

Wrapped in milk carton paper to see how things fit
Forward foot pegs

In cruising position, Alan incorporated forward foot pegs into his front mount.

Ninja 250 side
Helix 250 side

Checking alignment with a staight-edge.

The goal here is is to bend the little mounting tabs so the aluminum skin will wrap around without gaps. Much of the strength of the nose will come from the aluminum skin.

Foam Bulkhead

Before he can skin his Streamliner with aluminum, Alan makes a bulkhead across the front of 1" packing foam. Its main purpose is to funnel any and all air thru the radiator. Additionally, it will help to keep Alan dry in the rain.

Imagining

Alan is getting pretty excited about riding this thing.

Making tabs

The next step was to make 28 tabs (2 sets of 14 ... each slightly different) ...that will secure the aluminum skin without wrinkles.

The Master Parts to make a Streamliner Nose

I paint my Master Parts orange so I don't loose them. For the kit, I will mark the holes and draw a line around each piece on a sheet of paper for you to cut out. Drawings of these angle tabs will be included with each Streamliner Kit, too. If you make above (2) top pieces, (2) middle pieces and (4) lower pieces and angles in .125" aluminum and if you assemble them as per plans, you will have your own perfect Streamliner Nose structure. You can do this.

Ninja 250 side
Helix 250 side
A piece of scrap Lexan plastic serves as guide so Alan's boot does not snag when extracting his leg from cruising position.
7 1/2 pounds
Now Alan can wrap the structure with a trial piece of milk carton paper and extend it for his Ninja. I cannot add this bit of streamlining on my Helix because my legs don't go vertical on my Helix. I sit Feet-forward.

Note: While I am doing my best to make a Streamliner Kit that will fit any bike, there will be differences like this you will have to deal with.

Gotta set the nose on to see how things are fitting. Perfect. It is satisfying to see the same streamlined parts fitting both bikes. This is just like 41 years ago when I was designing the Windjammer Fairing.

The Windjammer had to fit every bike, too.

It is time to remove the old streamlining from my Helix.

I have been waiting a long time for this day. Oh Boy!

Removing the plastic is easy

All I have to do is pry out the plastic rivits to get to the aluminum structure underneath.

Its a rat's nest underneath

Four years of building and rebuilding - held together with about a million 8-32 screws. What a mess!

I decided to saw it off

Silver on silver looks pretty good, doesn't it?

Ready for the new nose

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