25. Side cover(See chapter 2 about the tools.)
    Click the right button of your mouse on the pictures to watch the drawings clearly.
    • Cut off a cardboard while fitting it to the side of the body and checking the design.
    • Make an accurate template based on it by means of a ruler and a pair of compasses.
      

    • Fit the template to the side of the body.Continue this process to make a good design template.
    • Copy the shape on an A5052 t=1.5mm aluminum plate.Draw a lines at a distance of 35mm from the shape but stretch straight line like the figure at the curve in the same length of AB.
      
      

    • Cut off the aluminum plate by means of a scroll saw.Finish the edge by means of a fine file.
    • Bend the plate at the four straight lines.Use a pipe to roll the curve portions.Join the both opposite edges accurately to weld well.
      

    • Weld the joined portion at the right side by means of a Tig welder temporarily.Then weld the right side firmly.While welding,charge sufficient welding rod to make reverse side bead convex.
    • Weld at the reverse side without any welding rods to make right side convex.
    • Planish the welding surface like the light or the gas tank.
    • Fit it to the frame to mark the portions which interfere with the battery or so on.
      

    • Make a riddle of the portion by means of an electric drill and connect the holes by means of a Tinman's shears.Finish it by means of a die grinder with a cutter for aluminum and a fine file.
    • Drill two 7mm holes in the side cover as shown in the figure.The cover is for APE I but the cover for APE II is similar.
      

    • Make a stay for fixing the rear of the cover as shown in the figure.Two M6 screw is for fixing both covers.
      

    • Connect both covers by bolts and fit it to the frame.Adjust the bending angle of the stay to make both covers right against the frame line.
    • Fix the stay to the rear pipe of the frame temporarily.Check again whether the covers are parallel against the fram.If not,correct them at this time.
    • Make two front stay like the divided rear star.Cut off them a little longer fitting to the frame and covers.Join the stays with the covers by bolts and fix the covers to the frame by bolting the rear portion to the rear stay.Adjust the length of the stays again.
    • Then weld them temporarily.Remove the covers and weld all stays firmly.
      

    • The side covers are a little bumpy so use putty and water proof sand papers to make them even.I always use urethan putty.
      

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