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Author Topic: GS400e Cafe Racer  (Read 451 times)

Offline Henrico123

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GS400e Cafe Racer
« on: December 11, 2020, 04:31:19 AM »
I recently bought an abandoned Cafe Racer project and decided to get it sorted out. It was intended to be a full nut and bolt build, It might still become one, but for now the aim is to get her running and looking a bit better so I can commute to work with the bike. Work done to date:

- Motor has been sent in to be re-built
- Frame has been cut to fix the horrendous job the original builder did
- Frame has been resprayed - will be done again as I have decided to alter the frame further to create a box where the wiring can be hidden
- I have ordered some goodies to fit to the bike (Mirrors, exhaust, lights, acewell dash etc.)
- I am busy fabricating a steel base for the seat and tail piece


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Offline SK Racing

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Re: GS400e Cafe Racer
« Reply #1 on: December 11, 2020, 04:46:29 AM »
Looks great. Keep us informed as you go along. I wish you success!!  :cheers:
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You don’t stop riding when you get old, you get old when you stop riding!
1939 Panther 600cc Single - Stolen, 1970 Suzuki 50cc - Sold
1969 Triumph Bonneville 650 T120R - Sold, 1981 Honda 750F - Sold
1989 Suzuki GS500E - Sold, 2004 Suzuki GS500F - Current ride

Offline Henrico123

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Re: GS400e Cafe Racer
« Reply #2 on: December 11, 2020, 04:57:40 AM »
Some Photos of work done to date
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Offline Henrico123

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Re: GS400e Cafe Racer
« Reply #3 on: December 11, 2020, 04:59:17 AM »
Yes I know the seat is ziptied on, it was the only way to hold it in place. The seat cover needs to be altered to conform to the tank
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Offline Henrico123

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Re: GS400e Cafe Racer
« Reply #4 on: December 11, 2020, 05:02:35 AM »
The paint job on the tank and tailpiece is not the best I have seen, but I am fortunate to have a spray booth in my workshop, so I will sort that out going forward. Next step is to fabricate a new battery box and move all the wiring into the space beneath the seat. Hopefully, I will have the motor back next week as well.
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Offline Henrico123

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Re: GS400e Cafe Racer
« Reply #5 on: December 11, 2020, 05:04:17 AM »
The original backside on the frame was a bit funky.....
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Offline Henrico123

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Re: GS400e Cafe Racer
« Reply #6 on: December 16, 2020, 11:57:21 PM »
Got some more work done on Ugly Suzy this week. Still waiting for the motor to get done, hopefully, I will have it next week.

I closed off the frame loop at the back so I can hide the brake light wiring etc, fabricated a new battery box to hide the battery until I can afford to do a Lithium battery and fabricated a panel to close off the frame above the back wheel (also to help hide wiring)

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Offline Henrico123

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Re: GS400e Cafe Racer
« Reply #7 on: December 16, 2020, 11:58:31 PM »
Some more Photos
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Offline Henrico123

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Re: GS400e Cafe Racer
« Reply #8 on: December 17, 2020, 12:00:04 AM »
Last of the progress pics. I really need to get a tig welder to neaten my welds. The new steel parts will get epoxy coated after Christmas
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Offline SK Racing

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Re: GS400e Cafe Racer
« Reply #9 on: December 17, 2020, 12:40:19 AM »
Looking great. Well done so far.  :cheers:

I'm dordling with my bike, though. The seat pan is taking up too much time. Still busy refining the mold.
« Last Edit: December 17, 2020, 06:09:26 AM by SK Racing »
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You don’t stop riding when you get old, you get old when you stop riding!
1939 Panther 600cc Single - Stolen, 1970 Suzuki 50cc - Sold
1969 Triumph Bonneville 650 T120R - Sold, 1981 Honda 750F - Sold
1989 Suzuki GS500E - Sold, 2004 Suzuki GS500F - Current ride

Offline Henrico123

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Re: GS400e Cafe Racer
« Reply #10 on: December 21, 2020, 05:37:04 AM »
My Seat is also still attached with zipties, I still need to figure out how to attach it to the bike, I have run out of ideas....
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Offline Henrico123

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Re: GS400e Cafe Racer
« Reply #11 on: December 21, 2020, 05:41:12 AM »
So I have had a chance to play with the bike again today. Bought a used Airage pipe of a guy on FB for very cheap. I know it is not really Cafe racer style, however, I like the sound of these pipes and the shape. I still need to figure out the final placement of the pipe once the motor is back in the bike, but have mocked up a hanger in the meantime. The pipe extends a bit far to the back of the bike, I will need to shorten the Stainless slip-on part of the pipe a bit to move it in and create a bit more wiggle room at the back brake.
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Offline Henrico123

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Re: GS400e Cafe Racer
« Reply #12 on: December 21, 2020, 05:44:28 AM »
Mocked-up hanger. This was done out of 2mm steel, once I have finalized the exhaust position I will make one from 3mm plate.
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Offline Jim Knopf

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Re: GS400e Cafe Racer
« Reply #13 on: December 21, 2020, 07:31:59 AM »
Servus,

Nice, but the Exhaust is toooooo long!
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Offline Henrico123

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Re: GS400e Cafe Racer
« Reply #14 on: December 22, 2020, 03:27:46 AM »
The more I look, the longer it gets!  :laugh: But in all seriousness, yes, it is too long. Hopefully, I will have the motor back on the 5th of January then I can get a better idea of what will sit where. Also, I realized this morning that the hanger might look better fitted the other way around.
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Offline Henrico123

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Re: GS400e Cafe Racer
« Reply #15 on: January 08, 2021, 03:28:58 AM »
Due to Family visits over the holidays and work commitments, I have not gotten much done to Ugly Suzy. I am still waiting for the motor, getting a bit peeved with the rebuilders as they keep making promises that they do not keep, but hopefully, I will have it in the next week or so. In the meantime, I have redone the exhaust hanger and swapped it around so the pointy end connects to the exhaust, looks way better now. Still need to sort out the exhaust placement once I have the motor.

Will probably be re-painting the bike as well in the coming month, our spray booth is getting installed at the moment, cant wait to use it. I just need to decide on a paint scheme, but I am leaning towards the Gulf racing colours, but instead of doing a flat blue, doing a metallic blue.

I am thinking of doing a GSX400R frontend, there is one for sale locally for a good price. Has anyone seen such a conversion or know of someone that has done the GSX400 frontend conversion? I know some guys do the GSX750
« Last Edit: January 08, 2021, 03:30:09 AM by Henrico123 »
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Offline Henrico123

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Re: GS400e Cafe Racer
« Reply #16 on: January 12, 2021, 12:31:31 AM »
Quick Update, I have decided to purchase the GSX400r frontend. I Will be picking it up on Thursday, it seems that the bearing sizes are the same, so hopefully it will be an easy fit, but I will do a write-up for anyone else considering the same swap once I have it.
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Offline Henrico123

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Re: GS400e Cafe Racer
« Reply #17 on: January 14, 2021, 04:25:26 AM »
Thursday has finally come. now O just need to get this thing fitted :woohoo:
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Offline Henrico123

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Re: GS400e Cafe Racer
« Reply #18 on: January 14, 2021, 07:22:08 AM »
I managed to get the Front end test fitted. I will need to make a spacer for the stem, as it is slightly longer, but bearings are the same, so it fits for all intents and purpose. I will do a full write-up on the front end fitment once I reassemble it with the correct spacers.
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