GS500F Restomod Street Tracker

[Sporty]

Looking good as is the rear of the frame.

I like the seat making!  Are you going for a level seat (not sloping downhill)?

[SK Racing]

Yes, I'll make the seat as level a I can practically get it, with a hump at the rear for looks. I was forever sliding downhill towards the tank on the standard seat. It may be fine with low clip-ons, but not with a high handlebar.

[cbrfxr67]

Love me some seat makin'!

[SK Racing]

Adjustable rubber bumper feet will screw into the underside of the seat pan and rest on the subframe.




I have to make stand-offs for the two front bumpers since the front of the seat pan sits higher than the rear to clear the starter solenoid which is quite a bit taller than the other electric components - even the LiFePO4 battery.

Started laying up some fiberglass for a mold for the stand-offs onto which the rubber bumpers will mount. It's been years since I last worked with composites. The plug for the mold was turned from Delrin.




The plug and the first mold that was released. This is time consuming work but necessary.

[Sporty]

Looking good, can't wait to see more!

[SK Racing]

Thanks Sporty. When I saw all the bubbles in the second (and first) mold, I decided to make new molds and cure them under vacuum. But I have to fix the vacuum pump first. The flexible coupling disintegrated while I was testing the pump today. A new coupling will be here tomorrow.

[Sporty]

Thanks Sporty. When I saw all the bubbles in the second (and first) mold, I decided to make new molds and cure them under vacuum. But I have to fix the vacuum pump first. The flexible coupling disintegrated while I was testing the pump today. A new coupling will be here tomorrow.

It looked great and no bubbles were visible in the photo.  I like creative hand work... small or large. Anyone can order from a catalog, but making things is more satisfying to me.

[SK Racing]

I like creative hand work... small or large. Anyone can order from a catalog, but making things is more satisfying to me.

I'm 100% with you on that. I like making things that you can't buy. Bespoke stuff; One-off designs. Like my GS500 street tracker for instance. There won't be another one like it once I'm done. I think we all crave individuality, but few can actually make it themselves. How lucky we are.

You have probably seen the online bike magazine bikeexif.com. Each week a few custom-built bikes are presented. Some of them are truly masterfully built.

[SK Racing]

The making of the foam plug (male mold) for the seat pan is taking up so much time, it's frustrating me big time.

Currently adding blue foam around the seat release and shaping it. I hate this kind of work, because if I make a mistake I'm going to want to start over. So I procrastinate a lot. In the mean time, I'm also getting all the supplies together to pull a light vacuum on the seat pan while the resin is curing. That means having to seal around the steel pipes of the subframe.

At least the vacuum pump is sorted out now. The vacuum can be varied from light to quite strong via an Arduino based controller that I built about a decade ago. This project will need only very light vacuum otherwise it'll crush the foam.

[Sporty]

That's going to be so nice.  Will it be a reusable mold?

[SK Racing]

That's going to be so nice.  Will it be a reusable mold?

Afraid not. The foam will probably break when I try to release the seat pan from it. But I don't mind. The seat pan will only fit my bike anyway.

[SK Racing]

The mold for the FG seat pan is taking much too long, but it is nearing completion now. I'm busy with the final touches and refinements. I'm using XPS (expanded) foam, painted with Dulux Supergrip acrylic undercoat as it blends well with light-weight spackle filler, which sands easily. I've already lost count on the number of coats that went on there, with filling and sanding in between. Fortunately, I'm enjoying this kind of creative work, since I don't design and build model airplanes anymore and this project satisfies my creative urge.

[iamhiding]

Some interesting elements in the mix, looking forward to seeing them together 

[Sporty]

The mold for the FG seat pan is taking much too long, but it is nearing completion now. I'm busy with the final touches and refinements. I'm using XPS (expanded) foam, painted with Dulux Supergrip acrylic undercoat as it blends well with light-weight spackle filler, which sands easily. I've already lost count on the number of coats that went on there, with filling and sanding in between. Fortunately, I'm enjoying this kind of creative work, since I don't design and build model airplanes anymore and this project satisfies my creative urge.

Getting better all the time!

[SK Racing]

The mold is done and ready. Just waiting for the right conditions to lay up carbon and fibreglass.

[SK Racing]

First post this year! But I've been working on the bike, bit by bit, almost every day. The fiberglass work turned into a nightmare and I vowed to never do it again. EVER!

Finally, the seat is done and I rode the bike for the first time in over 14 months. 



Next, the tank and wheels will get painted, and the new knobby tires put on - hopefully in time for the DGR (Gentleman's Ride).

The underside of the seat pan looks good in carbon fibre.





After I've shaped the foam, the seat was upholstered by Dion Korkie of Leatherman D, a renowned bike seat upholsterer in South Africa, who happens to be located in my city.



A lot of planning and work went into getting the electrics to fit under the seat with nothing sticking out underneath - an early design requirement and the main reason I went the Lithium Iron Phosphate battery route.



More pictures to follow once the tank is painted...


EDIT: Forgot to mention, the R/R has been relocated to the front - under the headlight.

[cbrfxr67]

man that is clean.  Love it!

[SK Racing]

Here's a pic to show what has been done lately:

Wheel rims painted with 2K and new tires fitted. The rims look really good and shiny. Other new parts fitted: Brake rotors and pads, braided steel front brake line, handlebar switches, handlebar levers, bar end indicators, front and rear sprockets.

The rear "brake reservoir delete" looks great and works fine.



Just waiting for the tank to be sprayed now. The color has finally been decided and the paint has been bought. It is "Porsche arrow blue".

[cbrfxr67]

going to be 'mazinnnn!

[SK Racing]

going to be 'mazinnnn!

Thanks cbr. I really hope so.

There are so many little details to take care of in a project like this. For instance, while refurbishing the fuel cap, I discovered why the little flap covering the key hole wouldn't stay down anymore. The spring had broken. So I decided to make a new spring - a craft I learned a few months ago when I disassembled my trusty old vernier caliper to clean and lubricate it. Of course I didn't know to look out for a little spring inside and lost it. Found a YT video on making springs from piano wire and voilà! ... a new spring!

So, I made a new spring for the fuel cap flap and after a few tries, realized that it has to be properly tempered. Then I found a blog on how to temper springs and this is the result. The spring started out all shiny when I made it, but now it has a blueish color from the tempering process. When you flick it now, it even sounds different than before tempering.