My GS500 project.... updated 12/2/09

[kappa2006]

Hey everyone....Just thought I'd start a post about my current project.  I'll let the pics do the talking.


Started off with this:


A 2001 GS500e with only 2600 miles on the clock.....and:


A bent frame:


The bike was t-boned when a driver ran a red light.  Insurance company totaled it.  But then I found this:


A 1993 GS500e, with about 15k miles, that's seen better days, but at least the frames straight and the title is clean.  So I got started right away and:



Completely stripped the 93 down to the bare frame.  I must say, the easiest bike I've torn down to date.  Prob took about 4 hrs total, while keeping all of the parts organized.  Here's a few other pics:  



Nice and straight!



Possibly the heart of a future project GS500GoKart?

Time to prep the 93's frame for paint! .........to be continued.

[makenzie71]

I see beemer wheels, an R1, and an air cooled four...looks like a GS 850...spiffy.

[kappa2006]

you're 2 for 3.  That is an R1....My roommates ridiculous 2007.  and that is an aircooled 4 cylinder, but its actually an 1100, out of a 1984 Kawasaki 1100LTD, which is pretty much just wasting space in my garage.  The motors good, but it came out of an unregisterable frame.  Lastly, you're close with the rims.  They are off of a german car, just not a bmw.

[kappa2006]

I've been ridic. busy lately, but finally got some free time to work on the bike.  Decided I was going to mock up my new subframe on the parts frame, and then transfer it over to the good frame once its finalized.  So I went at the damaged subframe with my cutoff wheel....






and heres a very rough sketch of the subframe design I'm going for.  I'm going to be using 1" by 1" square steel tubing.



and another look at the damaged subframe....

[O.C.D.]

Keep it coming, keep it coming.

This is exactly what I needed to see!  Be sure to take lots of pics and be as detailed as you can be.  Make sure to be detailed about the frame and how you paint it. 

[Roadstergal]

Very nifty.  I'm not a fan of the docked-tail look, but I appreciate a well-done project.

[kappa2006]

Today, I started work on the new subframe.  Started off by grinding down the gs frame to accept the 1" square tubing.  Then I positioned both 2 foot sections of tubing onto the frame...



Now it's time for the two supports for the main tubes.  Simply mocked it up, cut the basic angles I needed, and shaped with the grinder to get it perfect.  Then tacked it in place.....




Now the hard part....making a matching support for the other side.  But it ended up being easier than the first side was.  And here's how I left her today.......








to be continued....

[O.C.D.]

 

[kyle_99_gtp]

outstanding work, keep the pictures coming! I think it will look awesome once finished. heck it looks cool now!

[Ed500]

great thread. keep us posted! 

[Dj Hunny]

oh gosh, i'm addicted to this build. Can't wait to see more progress on the project.

[The Buddha]

OK so you hacked off the straight frame  ...

Then you're fitting the new style seat onto the rails you are welding on ...

You see, there is a better way to fit that seat on the old frame, I did it several years ago to cheesy/se7enty7's bike which he sold later to Tarzanboy.

I dunno, what is your final goal, cos you're not throwing on the R6 or GSXR tail like the others do, not that I am a big fan of that ...

Cool.
Buddha.

[JEREMY JOCK]

Looks like this is gonna be sweet.

[Chanse]

Props for the effort, and for those asking why he's cutting a perfectly good frame when he could have done the same thing to the old one. I would have to say clean title. I wouldnt have worried about it personally, I would have done it all on a salvaged frame, but regardless cant wait to see it done.

[kappa2006]

Thanks for all of the feeback everyone.  and Chanse you are correct.  The original gs I had was totaled.  and to get that registered, I would have had to either...have a licensed salvage repair shop repair the bike and document all receipts ect (very expensive), or attempt to clean the title in another state (ie. sell the bike to a friend out of state, fix it, and have them register it, then finally sell it back....paaaain in the ass)  So instead, I bought another gs with what was thought to be a blown motor, but had a clean title.  I was originally going to just swap everything over to the good frame and call it a day.  But then I started looking around customfighters.com....... and I decided to go all out and design my own custom gs.  I've been meaning to do a project like this for a while, and now finally have the opportunity.  

[gregvhen]

Thats great! 

With that 1 inch sqaure bar, does the original gs fram slide into that? or is that a welded butt joint? i may doing something similar. not for bent frame but for looks.  Also in the future I will need to know hos to make my own seat for previously said project.

[kappa2006]

The 1" square tubing slides over the gs frame, after you grind down the paint.  Its a tight fit height wise, but width there's extra room, since the frame isn't made from perfect square tubing.  I'll be building up the gs frame on the sides to make the fit even tighter, to ensure no side to side play.  As for the seat, I'll be using a one off of a 2007 R1.

[ineedanap]

Work faster!!!  I want to see the final product.  Sounds like it's going to be pretty cool. 

[kappa2006]

With the little free time I had this weekend, I did manage to get some work done, and received a few things in the mail as well.

Now that I know the angles of my subframe are going to work when the bikes assembled, its time to get the good frame ready for the swap.  I made identical cuts, removed the unnecessary  brackets, and cleaned up the mating surfaces.



Now if everything goes as planned, I should have the subframe on the this frame by wed. and can start fab'in some cross braces. 

I also disassembled my 2 bro's can....

All ready to be chopped.

and finally, some new parts.....

2006 R6 rear shock


drag bars


2007 R1 taillight


and some new gel grips  

Hoping to have the frame completed by the end of the week.  Then its on to the tail fairing.

[kappa2006]

Today I finalized the rear subframe and welded it to my frame.  Came out perfect.  Now all I need to do is weld the cross braces in and then I'll be able to finish weld the frame and grind it down smooth.  Then off to powdercoating!




and just a cool action shot