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Sportster Fuse Cover

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Posted by "Romain" here's a great idea to keep the water off the fuse panel in the sportsters.

A while back someone had mentioned a cover for the fuses on the Sporty.

After a little trial and error, I have made a cover for my Bike, a 07 1200 Custom and it seems to work O.K.

I don't know if it will fit on other models but if it's useful to somebody out there, I'll be glad to have made a contribution in return for all the good advice I have gathered on this forum.

It's pretty easy to make out of stiff plastic. (I used a piece of clear toy packaging, courtesy of my grand daughter.) It needn't be clear but clear plastic is easier to come by.
N.B. Don't use plastic that's too thick as it will make your work harder and might be more difficult to fit, It's only a cover and doesn't need great structural strength.

I attach there are a couple of pics, a template reduce to 50% (because of the size limit) and the full size template as a zip file.

Print the template 100% (It's a good idea to check that the measurements correspond as some printers can alter the size of the document by a few mm. and it needs to be accurate to fit.

I made a stiff paper one first just to familiarise myself with the construction and to check the fit.

Cut and score for the folds, fold and glue together with the appropriate adhesive, depending on the plastic used.
N.B. If you use thicker material, cut the flaps inside their lines.

Though it's not strictly necessary to do so, it's easier to fit the lid if you remove the + lead from the battery and you might want to put a little dialectric grease around the base of the lid for a tight seal.

Be careful when using sharp blades. :yeahright

Just because the world is unfortunately run by lawyers, :x I have to say that anything untowards that might happen as a result of this post is your responsibility, not mine. Attached Thumbnails
 
Mr. Data, very nice post!!! i printed the template to exact measurements (it took me like 7 tries to get exact measurements on my printer). i will defenately try this out and let you know how it works.
 
A quick and "dirty" method is many parts we buy "off the peg hooks" have blow mold "blister pack" packaging. I saved about a half a dozen clear ones until I found one that was close to the right profile, used a utility knife with due caution per Romain' post and voila' it pushes in tight, under the housing and seat area, covering the fuses just fine....! Not as classy a job as Romain' but it looks and works fine. I still did a real good cleanup job and used dielectric grease on all the new fuses, contacts including the relay...still upset that the HD servicer threw the stuff out when he worked on my bike and did not replace it. But then, the new terminal insulator and cover I had to redo look "brand new" under there. Told you I am an optimist! :D
 
tried to print this out and also enlarge it so I can read them and no lck they become unread able.

You can high lite it and copy it, then open a word document and paste it there. From there you can make it as large as you wish.

You can also press "control" and the + on the keyboard and it will enlarge too.
 
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