Diary of my current project build ... with plentyo' pics

[werase643]

A stock ignition switch will fit!!!!! in the conversion.....

[dgyver]

A stock ignition switch will fit!!!!! in the conversion.....

Yes sir! and even locks 

[werase643]

I need another washer under the top tripple to get it to lock.....

[NiceGuysFinishLast]

I would murder an's blowup sheep doll for that exhaust..

[bubba zanetti]

Great now I have the biggest case of GS envy ever.

That is looking great there.   

[Alphamazing]

I would murder an's blowup sheep doll for that exhaust..

Screw the exhaust, I want that suspension and brake set up!

Mmmm...

[Turd Ferguson]

Unreal, D!  I am so freakin' jealous.  Keep us updated.

[dgyver]

Finished welding the exhaust this morning. Still need to make a bracket to support the back of the exhaust can. This Micron can is internally supported unlike Yosh & M4 can that use the outer sleeve to support it. I shortened the can by 5".

Not sure about painting it yet but I do not want it black. Eastwood has a couple of color options. Thinking of either stainless gray or maybe silver.







There is about 4.75" of clearance to the tire. The shock is adjusted to its shortest length.
Not completly sure but I think there is about 1" of adjustment. The shock may be too stiff as sprung, a ride will tell.

[NiceGuysFinishLast]

Yeah.. I'd more or less sell my soul to put that exhaust on my bike.

[l3uddha]

I'm getting a funny feeling in my pants!

[Nepix]

I definatley want that exhaust on my bike

[RedShift]

dgyver, are you keeping track of how much this fun is costing you?  Just curious what kind of a tab you've run so far.

[dgyver]

dgyver, are you keeping track of how much this fun is costing you?  Just curious what kind of a tab you've run so far.

I have been keeping a spread sheet with the parts cost and an estimate of the time for each install & fabrication. I know there is no way I will ever recover my labor but just curious.

Hard to believe that I have only have about $1500 in the bike now, including the motor but that is going back to my track bike after I build another motor. The next motor may run up to $500. So far, the most expensive parts have been the tires and then the forks. I have been buying and selling parts for several years. I love buying someone out of all their parts, selling enough to pay for it and then the rest is free. That is how I got the motor (w/ 78mm pistons, ported head & megacycle cams).

[dgyver]

For those that do not like bleeding GS brakes......try bleeding twin 6-pots with 2 separate lines and without speedbleeders. I do have a couple .... but .... they are the wrong thread pitch. Oh well, after about 1.5 hours I have front brakes that you can sneeze on to do a stoppie.

I decided (for now) not to use EBC HH pads eventhough I have a new set left over from my TLR. Doubtful the I will need them. So instead I installed Ferodo 4004SS pads. I had them on my TLR for about 2000 miles before switching to HH pads. They worked good on the Tiller but the GS is about 100lbs lighter, so they should feel much better.

Also, I installed Fastline stainless braided lines with a blue cover. One of my ebay snags....new for $10.

And for the reservoir, I used a Brembo. It was only $15 (from yoyodyne.com) compaired to $45 from Suzuki. It mounts different so another bracket will need to be made.

[groff22]

Dgyver, it looks quite nice ... the swing arm and exhaust, are they touching? They look quite close to each other.

[dgyver]

Dgyver, it looks quite nice ... the swing arm and exhaust, are they touching? They look quite close to each other.

Thanks.

No, not touching. Plenty of clearance...about 1/2"-3/4" on the side and even more at the up-bend. The closest spot is the lower bolt for the shock. It is about 3/8". But the shock can only move away from the pipe. I could have made more clearance if I removed the catalytic converter. It took a long time to position everything correctly, especially not wanting to cut off too much then having to deal with a short pipe.

The next area of concern is the seat. The top bend is very close to the seat pan, maybe 3/4". I am planning on cutting the pan to add clearance for the pipe. I will be using Great Stuff spray foam to fill the void between the pan and the race tail, for support and connect the two. Of course I will need to make baffles to retain the foam in several areas. Probably add some sort of heat shield as well. Do not need my butt the catch fire.

[dgyver]

Here are some close-ups of the exhaust clearance at the swing arm (along with my helper)....




and the lower shock mount. That is a stock through drilled GSXR bolt.

[GeeP]

Does the chief inspector approve?

[dgyver]

He is looking for something to chew on, especially rolling tires.

[NiceGuysFinishLast]

Hey D..how bout wrapping the exhaust in header wrap before throwing the great stuff in?