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I went ahead and made a custom backrest extesion for my 2013 Burgman 400. I decided to not go with the other options out there as i really wanted to keep the existing "Red stitched" butt bump the 2013 comes with. I did want to pay the price of the other companies, so i made one my self and i am happy how it turned out.

Plus i had a lot of fun tinkering with it:D
 

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Discussion Starter #2
Custom backrest extesion for my 2013 Burgman 400

I went ahead and made a custom backrest extesion for my 2013 Burgman 400. I decided to not go with the other options out there as i really wanted to keep the existing "Red stitched" butt bump the 2013 comes with. I did want to pay the price of the other companies, so i made one my self and i am happy how it turned out.

Plus i had a lot of fun tinkering with it:iconbiggrin:

So I thought i would provide some pics of the process along the way...

1st Stage to remove existing Butt Bump and mounting frame and mark up a cardboard template...
 

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That is what I did on the backrest for my 06 400. Not hard to do at all.

I've also helped others do the same on both early and late model 400s and on 650s.

If you want to look at what I did there are pictures in my gallery. Link is in my signature. Look for the sub gallery labeled Little Blue, my 400S and open it up.
 

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Then had to determine size I wanted (mostly height).
 

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Thanks Buff! I will compare after I add my other pics:)


Next was a thin prototype to do a generic test;)
 

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At this point I was thinking I was in the game with being able to accomplish what I wanted. I picked fabric and other materials (bolts, etc.) and started the final plan. I had to replace the existing short bolts that were in the current butt bump. Soooooo, I had to pull off the seat cover on the bump peice. Basically removed the staples and had to pull out the old bolts.

I found a quality vinyl I liked that would cover the extension as well as a seperate cushion in the front to support the lower back/butt. I also wanted to cover the mounting bracket.
 

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completing the mounting bracket...
 

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Discussion Starter #8
Next the main extension pc...
 

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Finally the main assmbly with pad mounted all together...
 

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And LASTLY...on the bike!:D
 

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i really like your design, i got a bearcat but didn't really fit me cause i miss the bottom back support, but your design covers it pretty well. good job bud.
 

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Very nice writeup and photos. I just bought a 2007 Burgman 650 that the PO had done a similar setup with, but his mount pushed the backrest forward a couple of inches. Not a big deal except it pushed me towards the narrower part of the seat, which became uncomfortable after an hour. (I'm 5'11' and 160 lbs) I removed the adapter and am back to stock. Your adapter seems to keep the backrest in about the same position as far as forward/backward. Well done.
 

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Discussion Starter #13
i really like your design, i got a bearcat but didn't really fit me cause i miss the bottom back support, but your design covers it pretty well. good job bud.
Thank you for the kind words. I was worried that I would still get the support on the lower back/butt area and not the extra benefit the extension was supposed to provide because of the way I built it. But it worked really well in both areas. :cool:
 

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Discussion Starter #14
Very nice writeup and photos. I just bought a 2007 Burgman 650 that the PO had done a similar setup with, but his mount pushed the backrest forward a couple of inches. Not a big deal except it pushed me towards the narrower part of the seat, which became uncomfortable after an hour. (I'm 5'11' and 160 lbs) I removed the adapter and am back to stock. Your adapter seems to keep the backrest in about the same position as far as forward/backward. Well done.
Thanks as well for the comments. I do get good support in both areas. I designed the extra padding area with Velcro so I can change to a different size later down the road if I need to. Or if it starts to sag for any unforeseen reason. I wanted to have an option and that is why I didn't build it as one piece.;)
 

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Nice work.
 

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Very neat job, Joe.
Like Fernando, I also purchased a Bearcat backrest. At first I thought it would be just the ticket but after a ride or two I felt that I was riding on the hard part of the seat where the stock buttrest used to be. After doing some more research I ordered a 3brothers back rest, which is very similar in design to yours. I installed it a couple of days ago and I think it will work fine. You should get a lot of enjoyment out of yours, as well as having the satisfaction of having done it yourself.

George
 

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Thanks it works well. So far so good:D

I do have the satisfaction of having done it myself as well as only costing me around $20.00.

A couple pcs of plywood, bolts, nuts, foam, vinyl...that's about it! I got the vinyl on sale so that helped.
 
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