Author Topic: 1996 GS500 Basket Case Build into a GS600R  (Read 106571 times)

Offline cbrfxr67

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Re: 1996 GS500 Basket Case Build
« Reply #20 on: April 21, 2011, 02:17:54 PM »
Spent three hours on one bracket last night.  Bottom left behind engine.  I just couldn't get the angle right, or the hole lined up or something or other.  Finally got it tacked in and called it a night.  I'm thinking I'll get them all tacked in good and solid, then drop the engine and weld them in nice without the engine blocking my angles.
"Its something you take apart in 2-3 days and takes 10 years to go back together."
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Offline tb0lt

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Re: 1996 GS500 Basket Case Build
« Reply #21 on: April 21, 2011, 03:03:04 PM »
As long as the engine is supported properly and doesn't put stress on the mounts to distort/move them between the tack and the final weld, that is the way to go.

Offline cbrfxr67

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Re: 1996 GS500 Basket Case Build
« Reply #22 on: April 24, 2011, 02:45:37 AM »
Got my 06 tank in with plenty of dents to fix but I like it better than the old 96 skinny style.  Picked up a rashed 05 600rr tail to fix.  On the lookout for a fe to start messing with too.  Today kept on with getting the mounts welded in.  Had to cut the lower frame removable piece to clear the oil pan.  I lopped off the mounting tab but that wasn't enough, so I had to cut it and reweld it in for more clearance.  Hoping to start the 'exhaust clearance' cut tomorrow as the 4 into one exhaust really needs some time & thought to figure out how to make it work.  Will probably have radiator clearance issues too, so considering a dual radiator set up, one on each side.  Will get some new pics when I finish all the mounts and get some progress to look at.

« Last Edit: October 09, 2017, 04:18:06 PM by cbrfxr67 »
"Its something you take apart in 2-3 days and takes 10 years to go back together."
-buddha

Offline cbrfxr67

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Re: 1996 GS500 Basket Case Build
« Reply #23 on: April 25, 2011, 01:45:36 AM »


So much for not cutting the frame too much.  Had to take out a good section on both sides to clear the exhaust.  Will weld back in tomorrow if time & energy allows.  Today, spent a few hours doing the same thing I've been doing. 
"Its something you take apart in 2-3 days and takes 10 years to go back together."
-buddha

Offline KlaXon

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Re: 1996 GS500 Basket Case Build
« Reply #24 on: April 25, 2011, 09:10:23 AM »
Dude this will be awesome bike  :bowdown:
Good luck to you. Keep going.

Offline Chancegs1996

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Re: 1996 GS500 Basket Case Build
« Reply #25 on: April 26, 2011, 09:06:08 PM »
Hey dad its me this is going to be a really good bike... Thx for doing it!!!  :2guns: :woohoo: :thumb:

Offline Fry

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Re: 1996 GS500 Basket Case Build
« Reply #26 on: April 27, 2011, 01:52:30 AM »
Awesome Build....Love your motivation...Following this thread closely, Great Work.
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Offline cbrfxr67

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Re: 1996 GS500 Basket Case Build
« Reply #27 on: April 27, 2011, 04:22:06 PM »
Last night finished welding in the clearance for the exhaust.  Tonite will remove the engine and final weld up the brackets with better angles, having the engine out of the way.  Then I'm thinking I'll either chop off the tail and start on that, or start on the harness.  :icon_question:
"Its something you take apart in 2-3 days and takes 10 years to go back together."
-buddha

Offline cbrfxr67

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Re: 1996 GS500 Basket Case Build
« Reply #28 on: April 28, 2011, 02:35:48 AM »

Tonite dropped the engine and dove into getting my welds right.  I swear that engine must only weighs 80 pounds.  I think half the tub of parts from the gs engine weighs more!  Took me about 15 minutes to get it out of the frame and then I spent the rest of the night welding.  Need more time in the day! Where is the zzzz icon?
"Its something you take apart in 2-3 days and takes 10 years to go back together."
-buddha

Offline tb0lt

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Re: 1996 GS500 Basket Case Build
« Reply #29 on: April 28, 2011, 03:17:26 AM »
This is moving pretty fast. Exciting stuff.  :woohoo:

Offline jeffdodge

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Re: 1996 GS500 Basket Case Build
« Reply #30 on: April 28, 2011, 02:36:00 PM »
Keep up the good work!  :thumb:

Offline cbrfxr67

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Re: 1996 GS500 Basket Case Build
« Reply #31 on: April 29, 2011, 02:03:45 PM »
Weld, grind, weld, grind, weld, grind,.....if I had more time this would be much more satisfying.  As it is, time blazes by and then I have to call it quits for the evening.  Here you can start to see what I'm going for on the frame mod to clear the exhaust.  I thought it would make things more interesting than just doing a square opening or boring cut.  It's getting there slowly,....
"Its something you take apart in 2-3 days and takes 10 years to go back together."
-buddha

Offline Shepa

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Re: 1996 GS500 Basket Case Build
« Reply #32 on: April 30, 2011, 06:27:24 AM »
Nice project!


Have you tried to fit CBR's airbox into the GS frame yet? Any clearance issues?
Later problem as I see it will be mounting the GS gas tank over it all...

I'm asking since I have the opportunity to buy relatively cheap '96. F3, so I'm very much interested in this conversion...  :thumb:
I've already considered puting an Bandit 600 engine (air/oil cooled) into GS, but it's way too big (in all directions).  :icon_mrgreen:

Keep up the good work!
I'm subscribing for this topic.
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Offline cbrfxr67

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Re: 1996 GS500 Basket Case Build
« Reply #33 on: April 30, 2011, 10:12:42 PM »
Yes I know the airbox is going to be a challenge.  I'm probably going to get to do something interesting!  :icon_lol:  Today I finally finished the brackets.  So I cut off the tail.  Purists please don't flame me.  Ok sure, tell me what you think.  All opinions welcome.  (GS taking a nap)Primed out frame work.  You can see I left the old brackets, except for on the removeable piece.I know, I know, I just can't stop cutting, grinding and welding.Not sure how I'm going to angle it yet.  I had to quit before I could make up my mind.  I don't want it to look too long.  Give me some feedback and I appreciate yays or nays.  Thanks.
"Its something you take apart in 2-3 days and takes 10 years to go back together."
-buddha

Offline 5thAve

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Re: 1996 GS500 Basket Case Build
« Reply #34 on: May 01, 2011, 12:27:57 AM »
I like the lines better when angled like in the 1st pic.

Awesome job you've got going there!  Man, I have to learn myself how to weld. I have an itch to chop something too.
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Offline jeffdodge

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Re: 1996 GS500 Basket Case Build
« Reply #35 on: May 01, 2011, 12:37:07 AM »
I also agree with that. Lines work better in pic 1.

Offline Big Rich

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Re: 1996 GS500 Basket Case Build
« Reply #36 on: May 01, 2011, 12:41:10 AM »
By the title, I thought this was gonna be a run-of-the-mill basket case rebuild. Obviously, I was mislead......

Great work going on here!
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Offline cbrfxr67

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Re: 1996 GS500 Basket Case Build
« Reply #37 on: May 01, 2011, 01:56:50 PM »
I might have to change the title,...to quote tb0lt, it's a GS 600 now.   :icon_mrgreen:
"Its something you take apart in 2-3 days and takes 10 years to go back together."
-buddha

Offline cbrfxr67

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Re: 1996 GS500 Basket Case Build
« Reply #38 on: May 02, 2011, 03:34:51 AM »
Today worked on the tail for a couple of hours setting it up and finally welded it on where I think it's right.  Need to go buy tubing and steel tomorrow.-edit I found another 600rr tail but it is different from mine.  I couldn't figure out why my frame covers wouldn't work with my tail but it's obvious now.  I have an 04 tail.  With that, I'll be re-modding the framework to fit this (real) 05-06 tail which go with my frame covers.
« Last Edit: May 02, 2011, 04:13:30 PM by cbrfxr67 »
"Its something you take apart in 2-3 days and takes 10 years to go back together."
-buddha

Offline jeffdodge

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Re: 1996 GS500 Basket Case Build
« Reply #39 on: May 02, 2011, 04:30:37 PM »
 :cheers:

watching...