New GS, engine seized. Diary of Rebuild/Testing - LOTS OF PICS!!!!!

[beRto]

Do you have a title for the bike? How did you transfer ownership without specifying a VIN? I think it is relatively inexpensive to run a check on a VIN to make sure it doesn't come up as stolen or otherwise... might be worthwhile in this case?

I'm sure you know this; it looks like you need to replace your brake lever.

What brand of brake lines are those? I'm told the stainless steel sheath will wear out if it is allowed to rub. Usually there is a plastic covering on the outside, but it doesn't look like yours has this?

Looks like the project is coming along nicely.

[utgunslinger13]

In arizona there is a special tag that is on the frame and that matched the numbers on the title so I wasn't to worried about it untill I started seeing all these other "signs" that something else might be up.  I haven't transfered ownership yet because to do that I will need to get it inspected and its not in shape to go get inspected obviously! 

I'm also in the process of moving to another apartment in our complex on july 12th that has a garage, and at that point the bike is going to be completely disassembled and then rebuilt from the ground up!  I might not even put the engine back in once I get it together.  At the very least I want to repaint (if not powdercoat) the frame, add the X1 subframe and seat, go to a wider rear wheel and maybe a small suspension upgrade (no plans yet for that - maybe progressives?), along with a new paint job on the tank and any other body panels.

[utgunslinger13]

So I got my last part in the mail, and along with moving this week, I should really start to have some fun with the frame!  After the move I plan on stripping the frame down, installling the X1 subframe and powdercoating everything a nice charcol or graphite color.  Similar to the top tripple trees I painted and posted pics of earlier.  I was however a little disappointed with the condition of the subframe and all the scratches that are all over it!
















Any ideas on cleaning this up?  I haven't worked with aluminum before and I want it to be up to par before it gets powder coated!

Thanks!

[utgunslinger13]

Anyone have tips for cleaning this up before I just give up and powdercoat it?

[Fry]

I am very fond of the brushed aluminum look...

Perhaps take a scotch brite pad and basically sand it all in one direction giving it that brushed, dull aluminum look.

[utgunslinger13]

So that won't damage the aluminum surface and will give the same lines as before?

[utgunslinger13]

Anyone?

[beRto]

We're you able to sort out the title issues with the bike? You may want to hold off on putting more money into this until you can work that out?

Sorry, I don't know anything about cleaning up aluminum...

[utgunslinger13]

I haven't, but if necessary I'll just get another frame to switch it over to.  I'm really not that worried about that end of things at this point.  I need to get my machinist to actually be able to meet up with me and get the engine done, and get moved into my new place this weekend before I start adding more things to my list of things to do. lol

Besides, I might need to get the bike inspected in order to title and register it and it is in pieces at this point and in no shape for an inspection.

[utgunslinger13]

Finally getting moved in to our new apartment and I'm ready to start working on the bike again!

Here is my new "work area"


I began working on cutting the tail section off:


Here is the tail section I cut off:


Here is the underside of the seat that I trimmed to get it to sit flush with the tank.


And here is a test fit of the seat, still need to tuck in the cloth around the seat and restaple but the stock lip under the seat is able to clasp onto the GS tank!



Next I'm going to do some more fitting/cutting for the subframe and see where else I need to trim to get it to line up.

Thanks,

Nick

[yamahonkawazuki]

Ahhh yes gotta love the beer can subframe btw heres a link to some MC salvage yards in AZ  http://www.fullthrottlecycles.com/links/ffa-Arizona.html

[birdman]

utgunslinger13, great thread here. 
That bike looks like it got used for submarine duty or something. 
Since you have seen the rust situation, I would also look at inspecting the tank since you have everything apart.

I may have to buy a basket case just so I can have a bike to customize, I really think this sort of work is fun.

Keep up the good work.

birdman

[utgunslinger13]

Thank you!  Its a lot of work but it'll be worth it in the end.  Once I finish the engine and the frame, the tank and forks are my next step.  Then the gauges and wiring, etc.

[utgunslinger13]

Did a little more work before it got to late to cut and grind anymore.  Reshaped the seat and restapled the upholstery, cut out some more frame to test fit the rear section.  Here are the results:



I've got the top lined up pretty well but still think I need to work on the lower rail lining up before I start making something to bolt the subframe in.



Let me know what you guys think!

Thanks,

Nick

[yamahonkawazuki]

dammit man youre giving me ideas now. i may have to alter teh john deere bike concept slightly

[Fry]

Excellent work....Nothing like going past the point of no return by whacking off the stock sub frame rails.

Like I said, take a Scotch Brite Pad (Green) and with a bit of water or WD-40 sand the Aluminum Subframe. You want to sand all in the same direction, and not up and down, I'd sand lengthwise on that particular part. Something about the wave Light Waves will reflect off of a vertically polished piece compared to a horizontally sanded piece. By doing this you'll get that brushed, machined look out of the aluminum and up keep is as simple as re sanding when needed. Or if you had the time and energy you could polish that piece, sure then you have to clean it and polish it to keep it from oxidizing but a Chrome Like finish on a piece that big would also look nice. Let me know and I can give you the steps on how to polish if your not familar with them, or you could send it to me  and I'd polish it for a $100.00.

In closing, this will no doubt be another killer GS and Project thread to follow.

[Jim Knopf]

servus,

its looking like this:



you can see, how to fix the bull rear on the frame.

and here the endresult:

[utgunslinger13]

Yeah thats a little more agressive angle than I was hoping to go for.  I have been following a project on here that I've picked most of the tips up from, I think GSTWIZZLE his his screen name on here.  His doesn't quite come to that drastic of an angle and I think it looks much more rideable.

As for polishing/sanding the subframe, I plan on powdercoating the frame and subframe once everything is completed.  Will they polish/sand the subframe smooth or should I make sure its in good condition before I take it in?

Thanks,

Nick

[ben2go]

Hey Nick,call your coater and ask what he recommends for sanding and filling imperfections.He may already have included that in the price.

[utgunslinger13]

Ben2go: I actually haven't spoken to one yet.  i just know thats what I plan on doing.  But when I do speak with one I will ask if its included.

Jim Knopf: I wish there were some better pictures of how they altered it to bolt the subframe on, the more I see the better idea I can get in getting it to fit.  But I think mine will have slightly less of a severe angle of the seat.




I was trying to keep it level or below the tank lines, and I think I'm pretty close where I am now:




what about any input on cutting out whats marked in green below and bending the rail down then rewelding it solid?  Any negatives about doing that to get it to line with the subframe?