27° ride to Cabelas with new crash bar installed

Definitely confirmed my nagging suspicion that it was too cold to ride without heated grips.  I purchased some hand warmers at Cabelas and did not have to stop to warm my hands on the engine on the ride home.

KLR links

Useful links:
http://klr650.net/
http://klrforum.com/
Eagle Mike KLR650 parts
http://www.leftcoastklrs.com/articles.htm (doohickey instructions)
http://www.leftcoastklrs.com/Install_a_torsion_spring.htm (w/ torsion spring mod)
http://www.klr650.marknet.us/doohickey.html (more doohickey instructions)
http://germz.org/klr650/
http://klr650.com/
Dual Star KLR650 upgrades
Touratech Guards
Big Cee Engineering
        Dash upgrade
        Schematic (.gif)
Paul's KLR650 site
Happy-trail.com KLR650 (1st gen) stuff
Twisted Throttle KLR650 ( ^ ) stuff
AltRider KLR650 (  ^ ) stuff
Building the Adventure Motorcycle
Alex Chacon's adventure mods / advice
Mastech crash bars (Columbia)
KLR650 Timeline (.pdf )
Gear Calculator

Repaired engine shrouds

The left shroud was cracked and the right one was missing the lower mounting peg (where it pops into the grommet on the tank).  I glued the crack with some Locktite adhesive and then used pop rivets, JB weld epoxy, and some new plastic to reinforce it.  I also reinforced the other side to help prevent breakage.

Riveting and reinforcing a broken shroud

Epoxy and new plastic reinforcement

Blurry pop rivets

Since the lower mounting peg was gone, I made a new one using Motion Pro 1/4" Tygon fuel line

I used a brass 1/4" NPT to barb fitting; I cut the threads off

I chose the 1/4" Tygon fuel line because it fit nicely through the grommet

Just pop it on and then snug the bolt to keep it on

Ugly, but functional.  Maybe kinda steampunk?

The new mounting peg components (4mm nut not pictured)