Friday, December 28, 2007

Chrome legshield addition

The Bajaj Chetak & Legend do not come with chrome around the legshield, but you can add after market chrome.

Here's what you'll need:
1) Cuppino chrome trim
2) Heat gun ($10 at Harbor Freight Tools)
3) Dremel tool
4) Thick workman gloves and rag towels
5) Screw driver
6) Painter's tape

Do NOT use pliers! Let me repeat that, under no circumstance are you to use pliers. Pliers will create small "dents" in your legshield trim. The guy who helped me install mine used pliers and I saw the dents in the making and told him to stop. Too late!

Prepare the chrome to fit over the black trim around your Bajaj's legshield. Especially around the curves, you may find that the split in the chrome legshield may not be wide enough to fit over your legshield. What you need to do is to use your Dremel tool to sand/grind this split so that it is wide enough. Here's how . . . with a Dry Erase marker mark the areas on your legshield that are too narrow. Now, with your Dremel tool ONLY grind the INNER SIDE of the split (this side is the side that goes inside the scoot and will NOT been seen by anyone). Do NOT grind the outer side (this side is visible from the front of your scooter) as you need as much of a lip as possible so it lies flush with the front of your leghield.

Using painter's tape protect the black trim and paint around your scooter's legshield. Wait until the hottest day of the year at the hour when the sun is at its hottest point and cover your scooter or put it in a metal shed along with the chrome legshield. The goal is to get your scoot and chrome legshield trim piping HOT so that the trim is pliable. After your scooter and trim has sat under the hot sun for a few hours ask a friend to come over and help you. Wearing thick gloves and using a rag towel to hold the left piece of chrome trim (note: the right side needs to go on second because it goes on top of the other piece where they meet) heat it with a heat gun until its near to hot to hold. This will take a while. Now align the trim with your legshield and ask yourself which direction (from top to bottom or vice versa) will require the least bending to the most. Work in that direction. You want to start with the least bending possible and you will find that the bigger curves will be less because you have straightened out the smaller ones first (for the most part). Have your friend hold the end of the legshield trim in place as you slowly shape the chrome to fit the curves on your bike. Take your time. As you move up have your friend follow closely behind with pressure.

Now repeat that step with the other piece of chrome. Remember to get it piping hot first. After you have it installed apply more heat to both sides. Working with your friend start from bottom to top on the first piece of chrome installed. Have your friend apply pressure and you are to secure a screw in place. Now your friend will apply pressure and the next screw hole making sure to keep the chrome pushed tight against the bike. Add the second screw. Repeat until done. Repeat on the final piece of legshield.

1) I do NOT like the pointed screws as they will damage your paint. The vintage bikes used a flat tipped screw to not damage the paint. You might consider investing in these.
2) This process is a big paint in the butt. Please take your time and don't rush it. It is not easy nor fast, but it looks great when done right.

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