Author Topic: 2005 GS500F | Scrambler Project  (Read 28185 times)

Offline Joester41

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Re: 2005 GS500F Project
« Reply #20 on: December 07, 2015, 07:21:01 PM »
Short update...

The plastic front fender came today, trimmed it up and mounted it.








Still designing the new battery box. Once that is done it will be on to the seat mounts, tail cluster, and glassing the seat pan. Hoping I can have all the parts designed before the end of the year.
Current rides:
2016 Duke 690
2016 Duke 390
2001 DR650SE
1975 DT175B

Past rides:
2008 WR250X
2005 GS500F Scrambler
1970 CT90K2

Offline Daeouse

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Re: 2005 GS500F Project
« Reply #21 on: December 08, 2015, 06:29:10 AM »
That looks damn good! :cool:
Jon "MotoSquirrel"
2009 Yamaha V-Star 950
My Blog!

Offline Joester41

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Re: 2005 GS500F Project
« Reply #22 on: January 18, 2016, 09:37:06 PM »
A few updates...

The last of my brackets are done, next thing is to get them welded on and then glassing the seat pan.



The new chain guard prior to bead blasting.



The new battery box prior to welding.

Current rides:
2016 Duke 690
2016 Duke 390
2001 DR650SE
1975 DT175B

Past rides:
2008 WR250X
2005 GS500F Scrambler
1970 CT90K2

Offline lucas

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Re: 2005 GS500F Project
« Reply #23 on: January 18, 2016, 10:48:28 PM »
Nice work,  are you planning on putting the fork brace back on?  I wonder how it handles without it.

Offline Shepa

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Re: 2005 GS500F Project
« Reply #24 on: January 19, 2016, 03:38:34 AM »
That looks damn good! :cool:
+1

:)



Sent from my toilet seat using HTC FartPhone

There he goes. One of God's own prototypes.
A high-powered mutant of some kind never even considered for mass production.
Too weird to live, and too rare to die.

Offline Joester41

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Re: 2005 GS500F Project
« Reply #25 on: February 13, 2016, 04:40:15 PM »
Update:

Battery box welded and first coat painted.






Seat brackets welded and first coat of paint.






And a picture post welding through a FLIR camera...

Current rides:
2016 Duke 690
2016 Duke 390
2001 DR650SE
1975 DT175B

Past rides:
2008 WR250X
2005 GS500F Scrambler
1970 CT90K2

Offline Daeouse

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Re: 2005 GS500F Project
« Reply #26 on: February 13, 2016, 05:31:30 PM »
Despite this thing being taken on a tangent that's not quite my cup of tea, I will say you're doing an absolutely incredible job and your work looks amazing! :thumb:
Jon "MotoSquirrel"
2009 Yamaha V-Star 950
My Blog!

Offline lucas

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Re: 2005 GS500F Project
« Reply #27 on: February 13, 2016, 10:02:33 PM »
I like the quality of your work.  What all are you planning to mount onto the battery box?  Looks like you got spots for bunches of things.

Offline Joester41

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Re: 2005 GS500F Project
« Reply #28 on: February 14, 2016, 05:53:58 AM »
I like the quality of your work.  What all are you planning to mount onto the battery box?  Looks like you got spots for bunches of things.

Thanks, I plan on mounting everything that was on the stock box, plus the rectifier and relays.
Current rides:
2016 Duke 690
2016 Duke 390
2001 DR650SE
1975 DT175B

Past rides:
2008 WR250X
2005 GS500F Scrambler
1970 CT90K2

Offline Joester41

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Re: 2005 GS500F Project
« Reply #29 on: February 21, 2016, 10:07:18 AM »
Update:

Electrical is done, here are some of the changes...

right side view of box, before everything is connected.


Left side before connections.


Modified harnesses.


New tail connectors.


Everything connected and routed.

Left


Right
Current rides:
2016 Duke 690
2016 Duke 390
2001 DR650SE
1975 DT175B

Past rides:
2008 WR250X
2005 GS500F Scrambler
1970 CT90K2

Offline Daeouse

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Re: 2005 GS500F Project
« Reply #30 on: February 21, 2016, 12:26:52 PM »
That is some beautiful wiring harness work there, and everything has come together beautifully! VERY well done indeed! :thumb: :cool: :bowdown:
Jon "MotoSquirrel"
2009 Yamaha V-Star 950
My Blog!

Offline MotoFuzzle

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Re: 2005 GS500F Project
« Reply #31 on: February 23, 2016, 01:25:58 PM »
That is some quality work; well done.  I'm trying to source some steel to do the same seat loop.  Did you use scrap GS500 subframe, or were you able to find the rectangular tubing fairly easily?

Offline Joester41

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Re: 2005 GS500F Project
« Reply #32 on: February 24, 2016, 10:38:03 AM »
That is some quality work; well done.  I'm trying to source some steel to do the same seat loop.  Did you use scrap GS500 subframe, or were you able to find the rectangular tubing fairly easily?

Thanks, It helps to have access to a machine shop and an uncle that welds race car frames for a living  :thumb:

Its actually 1" x 3/4" bar... its a hair larger than the tubing, but it worked pretty well after the weld seams were ground.

I've seen others use smaller tubing and sleeve it inside the frame, makes for an easy weld and looks pretty clean.
Current rides:
2016 Duke 690
2016 Duke 390
2001 DR650SE
1975 DT175B

Past rides:
2008 WR250X
2005 GS500F Scrambler
1970 CT90K2

Offline Big Rich

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Re: 2005 GS500F Project
« Reply #33 on: February 24, 2016, 11:55:31 AM »
Wow Joe, that is some great work for sure. Looks factory!
83 GR650 (riding / rolling project)

It's opener there in the wide open air...

Offline Carltheproducer

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Re: 2005 GS500F | Scrambler Project
« Reply #34 on: February 25, 2016, 12:34:47 PM »
Love what you're doing buddy. Very inspiring only if I had a garage, spare time and the skill set you had, I would do everything you're doing thus far.

Offline lucas

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Re: 2005 GS500F | Scrambler Project
« Reply #35 on: February 25, 2016, 01:02:37 PM »
Vicarious motorcycle building

Offline Joester41

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Re: 2005 GS500F | Scrambler Project
« Reply #36 on: February 27, 2016, 02:37:01 PM »
Update:

Got the seat pan glassed, just need to wait for it to cure, pop it off, and trim it.

masked off


foil taped


glassed
Current rides:
2016 Duke 690
2016 Duke 390
2001 DR650SE
1975 DT175B

Past rides:
2008 WR250X
2005 GS500F Scrambler
1970 CT90K2

Offline Daeouse

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Re: 2005 GS500F | Scrambler Project
« Reply #37 on: February 27, 2016, 06:49:47 PM »
I'm definitely keeping a sharp eye on this work! I always wanted to see a seat build done in a proper, methodical, manner. :thumb:
Jon "MotoSquirrel"
2009 Yamaha V-Star 950
My Blog!

Offline ShowBizWolf

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Re: 2005 GS500F | Scrambler Project
« Reply #38 on: February 28, 2016, 10:47:49 PM »
I'm with ya Daeouse, this looks so clean!! And since I just started working with fiberglass a little over a year ago, I am eager to learn from this seat process  :bstar:
Superbike bars, '04 GSXR headlight & cowl, DRZ signals, 1/2" fork brace, 'Busa fender, stainless exhaust & brake lines, belly pan, LED dash & brake bulbs, 140/80 rear hoop, F tail lens, SV650 shock, Bandit400 hugger, aluminum heel guards & pegs, fork preload adjusters, .75 SonicSprings, heated grips

Offline Joester41

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Re: 2005 GS500F | Scrambler Project
« Reply #39 on: March 02, 2016, 07:57:08 PM »
Update....

I wasn't 100% content with the first seat pan, so I decided to do another (since I had all the materials and everything set up).

The first pan (with front wings) i did about 5 layers, in this order:

1. cloth (woven) precut for hardware
2. mat (unwoven) precut for hardware
3. mat reinforcement, down the center overlapping the hardware locations precut for hardware
4. nuts installed
5. mat precut for hardware
6. cloth precut for hardware

Close-up of the front hardware inserts from the first pan



Tank-tab made out of 3/16 kydex sheet (heat-formed)



The first seemed to get pretty messy with the unwoven fiberglass mat. I figured I could get the same amount of strength by alternating directions of the weave. So, I did the second pan (no wings) in this order:

1. cloth sheet, precut for hardware
2. cloth panels under seat locations for 2 riders
3. hardware reinforcement
4. cloth sheet, precut for hardware
5. harringbone pattern strips of cloth, entire length
6. hardware reinforcement
7. hardware installed
8. cloth sheet, precut for hardware
9. 2nd cloth panels under seat locations for 2 riders
10. last hardware reinforcement
11. final cloth sheet



I modified my Kydex tab piece for the second pan. Used 1/8 inch with the holes length-wise. I also modified the pan shape a bit, tapering it down to the frame making the shape a tad stronger.

Another note, in order to stretch my fiberglassing time (doing it solo), I put 40 drops of hardener into four 8oz cups, pre-marked at 4oz (recommended 10 drops of hardener per 1oz of resin). This way all i had to do was dump the resin in up to the line and mix with a popsicle stick. I also had some extra pairs of gloves and trimmed-down brushes standing by for when they got gummed up. All said and done, i used about 16 oz of resin, 2 brushes, and about 3 pairs of gloves per pan.
Current rides:
2016 Duke 690
2016 Duke 390
2001 DR650SE
1975 DT175B

Past rides:
2008 WR250X
2005 GS500F Scrambler
1970 CT90K2

 

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