Whelp my stalled out GS project saw a flurry of activity these last few days. I finished rebuilding and mounting the Forks. Swapped out the Rear Wheel Bearings and begun the final stage of the project, building the sub frame to mount the Ducati Monster Seat.
This first pic shows the new upper rail mocked into place. Once the old rails are cut out and these welded in, the seat to rail gap will close slightly, I feel that I matched the angle of the seats upward horizontal line pretty good which is what I was after. Additionally the "Kick-Up" on these new rails positions the seats flat passenger's section on a equal, level plane wit the flat top portion of the gas tank when viewed from the side.
(http://inlinethumb55.webshots.com/37046/2391696550073478356S600x600Q85.jpg) (http://good-times.webshots.com/photo/2391696550073478356nHhOCe)
In this pic you can see the seats position, once mounted the passenger portion will be perfectly level with the flat top of the gas tank.
(http://inlinethumb26.webshots.com/4121/2160443460073478356S600x600Q85.jpg) (http://good-times.webshots.com/photo/2160443460073478356MgPnBH)
I was going to follow the lead of a fellow board member and cut out the lower bar along with it's bracing to the main frame spar repositioning a newly fab'ed one higher on the main frame however I may go a different route. First I plan on cutting off the passenger peg mounts as well as any other tabs and bracing just leaving the straight rail. Once the old top rails are cut out and the new ones welded in I will make a pie cut in the stock lower rail directly under the pie cut in the upper rail bending the stock lower rail up to meet the newly created rail . I'll cut the length so that once bent upwards it meets the new upper rail directly behind the pie cut/weld. Where the lower and upper meet I'll cut the end of the tubing to match the angle of the kicked up portion. I know some may feel it's hack to use the lower kicking it upward, that it's not original or doesn't match the level of work and thought put into the rest of the project or isn't sanitary enough, but I just may go with it. By doing so it will save me a lot of work by not having to cut the lower rails frame lug/support arae, boxing in that area, and fitting a new lower higher on the main frame. Time will tell though.
(http://inlinethumb23.webshots.com/42774/2148867670073478356S600x600Q85.jpg) (http://good-times.webshots.com/photo/2148867670073478356cYGHXQ)
Once the new uppers are welded in I'll make a cross brace using the same tubing welding it in a few inches behind the Pie Cut/Welded area. If I go with the option of bending the lower tube upward it will meet right where this cross brace will be going, with my Backyard Engineering skills I believe this brace along with the kicked up lower will provide enough strength to support a passenger as well as keep undue stress away from the pie cut areas?
(http://inlinethumb01.webshots.com/23424/2444043790073478356S600x600Q85.jpg) (http://good-times.webshots.com/photo/2444043790073478356QSfXtb)
In closing, here she sits waiting for more measuring, cutting and welding.
(http://inlinethumb03.webshots.com/2690/2844936840073478356S600x600Q85.jpg) (http://good-times.webshots.com/photo/2844936840073478356jpyzFq)
More Pics to come this week.
I'm looking at your setup and it seems you'll be stronger than the gs's if....
you're saying the lower STOCK rail that comes from the frame gusset (pie/whatever) up to the upper rail just under the rear most of the seat. you could re-use the heavy gusset already on the frame, cut out some of the weld for the new angle of the lower sub frame rail, and then put a slight arc into the lower sub frame rail. frenching it into the upper rail is going to look f%$king wicked, if that's what you're planning on !
just a vary mild (6' radius or so) rolled into the lower subframe rail would look soooooo awesome.
the entire subframe is going to be shorter overall length, so it will be less of a lever acting on the frame = stronger. i wouldn't worry about plopping a passenger on it, myself. those square tubes are stout by themselves, but 4 of them welded into (basicly) a triangle with cross bracing is really really stout.
have you considered which tail light you'll be using ? you may not want to taper the junction of the upper and lower sub frame rails too much at the rear if you have a largish light in mind, for aesthetics.
gonna love seeing the finished product here :)
Thanks for the feedback.
If I re-use the lower rail, I will strip it of everything and cut it to length, so that when bent upward (Bending it under and in the same manner as the bend of the top rail), it will meet and be Frenched into the area right behind the start of the Kick Up in the top rail which will also be the area where I run a cross brace between the two top rails.
This lower rail will meet up with the top rail about 2-3 inches past the visible weld in the top rail. I'm thinking that this lower rail bending and meeting in a almost vertical plane will act as a "Leg" to support the top rail from downward forces. Additionally this union area will be further strengthened by the square tubing cross brace that I will flush mount between the top rails, in phase with where the lower rail attaches to the top rail.
As for a Tail Light and Directional set up for the rear I plan on using something like the below picture bent to match the radius of the rear portion of the seat. It will be mounted so it tucks up flush with the seats underside.
(http://www.radiantz.com/cart/customflex.gif)
I can get a flexible dual circuit LED set mounted in a smoked clear tube that has L/R Amber Directionals that flank a center RED Brake/Parking Light. when operated, when not in use the smoked tube blends with the seat color. At the rear of the new frame rails, which will stop about 2 inches short of the seat length I will flush mount another square tube cross brace. Where the cross brace and 2 top rails meet and form a 90 degree angle I will cut triangles out of some new sheet metal and weld them in as gussessts. I will drill the centers out of these triangles and welded in some 8mm Nuts on the tops sides and use them to mount the tail light directional set up.
Looking good :cheers:
Those are some BAD ASS vise grips you have there :laugh: I have never seen a pair that big :cheers:
Quote from: scottpA_GS on June 02, 2008, 05:14:49 PM
Looking good :cheers:
Those are some BAD ASS vise grips you have there :laugh: I have never seen a pair that big :cheers:
Um, I never had a guy compliment me on the size of my tools, LOL....
I have a few even larger and with different ends used mostly for welding.
Looks like it's coming along nicely, can't wait to see the finished product.
i'm gonna watch this thread. this is going to be one awesome looking bike ! :)
Very nice work. Think this will be the best GS with a duck seat. Your welds look super clean too. Much better than the garbage was done at the factory. I've been going over my frame quite a bit and it's pretty shocking how bad some of the welds are. Keep up the good work :thumb:
Thank you for all the kind words, I don't know about the "Best" hopefully it will be on par with those that did it first, they were the inspiration.
I too think some of the secondary welds on the GS are pure rubbish, the ones on the main frame spar look OK, but the trash on the subframe is second rate IMHO and I am by no means a professional welder, just someone who can Arc Mig and tig in a decent manner.
Anyway more updates to come this weekend, matter of fact Ill grab a recent photo and post it up, yup the good old Milwalkee Saz All finally came out and I have entered the point of no return.
These pics will show the top rails that have been cut off, the point of no return. I haven't dressed the ends of them yet but will do so this weekend.
You can also see the top rails mocked up, once welded they'll line up perfectly with the Plane of the top stubs.
The pic with the seat is a bit deceiving, as I cannot spread the rails out enough in the mocked up fashion to have the seat rest on the new rails. Once I cut off the remaining top portion of the rails, and cut all of the accesory tabs, brackets and foot peg mounts of the lower rail, I'll be able to mock the seat up in a better fashion before mig'ing in the top rails in their final position.
I'm still undecided about bending the lower rail upwards to meet the top rail right behind the weld, or make a entirely new lower rail, having it come off the main frame spar at a higher point, creating a smaller, sleeker "Triangle" when viewwed from the side.
Opps, but long winded, heres the pics.
(http://inlinethumb24.webshots.com/40791/2628526860073478356S600x600Q85.jpg) (http://good-times.webshots.com/photo/2628526860073478356VqjEGq)
(http://inlinethumb01.webshots.com/43520/2765422690073478356S600x600Q85.jpg) (http://good-times.webshots.com/photo/2765422690073478356tFaXBu)
(http://inlinethumb25.webshots.com/42520/2312778300073478356S600x600Q85.jpg) (http://good-times.webshots.com/photo/2312778300073478356FJovMd)
(http://inlinethumb50.webshots.com/26097/2932575010073478356S600x600Q85.jpg) (http://good-times.webshots.com/photo/2932575010073478356SKTCvC)
(http://inlinethumb55.webshots.com/6198/2584585910073478356S600x600Q85.jpg) (http://good-times.webshots.com/photo/2584585910073478356pUTYXn)
(http://inlinethumb29.webshots.com/39132/2444561010073478356S600x600Q85.jpg) (http://good-times.webshots.com/photo/2444561010073478356kWRuJn)
(http://inlinethumb20.webshots.com/42067/2277065500073478356S600x600Q85.jpg) (http://good-times.webshots.com/photo/2277065500073478356kAnOfY)
That really looks good, how the passenger portion of the seat is level with the gas tank. Keep up the good work, I can't wait to see the finished product.
+1 on bucks comment about the looks of the seat and tank on the same plane.
that really looks nice.
i am green with envy looking at your garage.
Thank you for the comments I really appreciate the feedback both good and bad.
As for the garage, it's like every other garage in the world, NOT ENOUGH SPACE. Besides a Lathe/Bridgeport Machine it has just about everything I need except SPACE, Space and Air Conditioning, frigging 2nd straight 90+ degree day. Welding and Grinding in this heat sucks, I try to get what I want accomplished prior to 11a-12pm, yeah my neighbors love me.
I finally got the 2 upper sub frame rails welded in. In the pics some of the welds have been cleaned up a bit, but some look pretty ugly and need attention. I also got the front seat latch/enclosure done, just used the original GS seat Lock/Latch mount from the rear minus the Latch mechanism, welding it up at the front of the rails to receive the Ducatis 2 plastic forks on the seats under side that lock/wedge under this brace.
The seat mounts nice and level but let me tell you the stock frame, at least on this was a bit tweaked out. When I was mocking up the top rails I would put the level on the 2 top rails and the right was a bit low, about a 1/16th of an inch which affected me getting the newer rails welded in a level manner. I couldn't figure it out at first, it took me a while to check the stock rails to find out they were tweaked. I still have to cut about an inch off of the new rails length, put a cross brace in the rear, bend up the lower rails to meet the new uppers, put a cross brace in were the lower meets the upper, and figure out some trim for the underside of the Ducati seat that hangs over the newer rails on the sides.
I have sheets of this rubber coated steel industrial speaker grill that is totally perforated with holes a tad smaller than a bic pen. I might trim a horseshoe type shape that is formed fitted to the underside outside edges of the seat with this material. Also using this material I plan on making a package tray of sorts that is the width of the upper rails and about 4-5 inches long, sinking it between the upper rails in the front creating a tray that I can mount the electronics. Being perforated it will get plenty of air flow, being covered with a rubber coating it will be vibration resistant, and having all of the holes will allow me infinite mounting possibilities. I plan on mounting everything in this little tray besides the battery. The battery box will be trimmed and mounted above the shock upper mount right behind the K+N Lunchbox style filter which replaces the stock air box.
Well heres todays picture update:
(http://inlinethumb56.webshots.com/42999/2880799050073478356S600x600Q85.jpg) (http://good-times.webshots.com/photo/2880799050073478356GcyqPA)
(http://inlinethumb19.webshots.com/39890/2735256370073478356S600x600Q85.jpg) (http://good-times.webshots.com/photo/2735256370073478356DBvKeg)
(http://inlinethumb23.webshots.com/43030/2044490840073478356S600x600Q85.jpg) (http://good-times.webshots.com/photo/2044490840073478356AXKomh)
(http://inlinethumb44.webshots.com/41323/2948902170073478356S600x600Q85.jpg) (http://good-times.webshots.com/photo/2948902170073478356fPZKpa)
(http://inlinethumb04.webshots.com/42499/2595130890073478356S600x600Q85.jpg) (http://good-times.webshots.com/photo/2595130890073478356wEPNVO)
(http://inlinethumb53.webshots.com/28532/2179849080073478356S600x600Q85.jpg) (http://good-times.webshots.com/photo/2179849080073478356GUWGkA)
Your work is Great .. I cant believe ur going to use ...A) That Ugly Motorcross headlight , looks cheap and tacky .. Use A Single or Double Set up
b) get a 4.5 inch rim for a Fatter Rear tyre , it will make it look so much better , and fill the bike out morer
c) A stock front end , i say go the whole She bang and Get A Katana or something Front end , The Mighty Buddha has one that will fit right in ,
Otherwise incredable work , i just think ur going to have one of those Gs's that are going to make people want to mod the hell out of them , id say make it a show piece
With Gas Prices , would pay for itself in no time
and Loving the Buell ... You welding is much better that the Factorys :thumb:
Thanks man...
This bike and overall project is governed by money and realistic expectations. My main goal was to get it on the road again and save some money on gas, enjoying some street action. This project was only suppose to involve a fork oil seal replacement, and painting the tank flat black long with the removal of the chin and headlight fairing. So even though the members bikes here and along with their posts led me to get a bit out of hand with what I have and plan on doing, I still don't have much into the bike cost wise and realize it's limited potential without going overboard.
Maybe this coming winter I'll do a USD or Katana Fork Swap along with fitting a bigger wheel/swing arm but for not it's not a priority and realistically I cannot justify the expense and more than likely will just work with what I have.
Yeah the Light may look cheap but I like it and had it lying around plus it hides the wiring mess pretty good, though the whole loom will be reconstructed and moved around a bit so perhaps I could go with duals, Piaa makes a nice light with the halo rind around them, yet it's a hundred bucks or so that I could spend else where.
Anyway, work moves forward.
I didnt mean any offence each to there own ,but the tail is the issue with me , i like the 2001 one , i had a 1996 , but bought a 01 for the seat, i love the monster seat , damn sweet ,Loving it
Seeing all this work makes me wish I knew how to weld. :)
Quote from: Jay_wolf on June 08, 2008, 08:17:16 PM
I didnt mean any offence each to there own ,but the tail is the issue with me , i like the 2001 one , i had a 1996 , but bought a 01 for the seat, i love the monster seat , damn sweet ,Loving it
No offense taken, I appreciate your observations and am thinking about a different headlight set up....