Pyramid Hugger C/F Modification

[motoyoyo]

There has been some discussion about Carbon Fiber huggers lately on a different thread. I'm using the Pyramid hugger on my bike right now and although it appears to be a much safer alternative to another brand, there are some issues with it as well. After I mounted my Pyramid and rode for one day I noticed that the mounting holes were elongating causing the hugger to tip forward and touch the paralever arm at the very front of the hugger. The clearance is very close to the paralever to start with, about 1'4", so just a slight movement at the mounts will let the hugger ride on the paralever. This pic shows how it should look.



I was able to make a fix for the mounting holes that is so far holding up great for the last 3000 miles, which is a lot better than the original did at just 200 miles. I dug through my junk parts drawer and found a couple front fender mount washers for a dirtbike. They have a short standup in the center that was just about the same height as the thickness of the hugger.



The mounting hole had to be filed out large enough to slide the fender washers in from the backside and the two parts were epoxied together and lightly held in place, while the epoxy set up, on the bike to insure the proper positioning. After 24 hours the hugger was torqued down with the original rubber washers on the inside.



These pics show how they look from the front and the back sides...
They are permanently epoxied in place and are a solid part of the hugger now. There is now only metal to metal contact on the mounting bolt so the carbon fiber will not wear anymore at the mount. Since the mounting washers have a pretty good amount of surface area in contact with the C/F, the epoxy should do a good job keeping the mounts from slipping at all. These pics are after 3k miles and it still shows no sign of wear since I put them on.





The brake mount bolts were cut down to allow for the extra width of the fender washers on the backside of the hugger. You can also take more or less material off one or the other of these bolts to center the hugger up nicely on the tire. My hugger was a bit off alignment originally and this step brought it in straight. The other thing about this step is that you can also take a bit more material off each bolt if you need to center the hugger on a 5-1/2" rim.