Hey everyone....Just thought I'd start a post about my current project. I'll let the pics do the talking.
Started off with this:
(http://i53.photobucket.com/albums/g61/BKappa2006/DSC00874.jpg)
A 2001 GS500e with only 2600 miles on the clock.....and:
(http://i53.photobucket.com/albums/g61/BKappa2006/DSC00875.jpg)
A bent frame:
(http://i53.photobucket.com/albums/g61/BKappa2006/DSC00876.jpg)
The bike was t-boned when a driver ran a red light. Insurance company totaled it. But then I found this:
(http://i48.photobucket.com/albums/f214/SSjetta/Suzuki_sep09/IMG_7294.jpg)
A 1993 GS500e, with about 15k miles, that's seen better days, but at least the frames straight and the title is clean. So I got started right away and:
(http://i53.photobucket.com/albums/g61/BKappa2006/DSC00872.jpg)
Completely stripped the 93 down to the bare frame. I must say, the easiest bike I've torn down to date. Prob took about 4 hrs total, while keeping all of the parts organized. Here's a few other pics:
(http://i53.photobucket.com/albums/g61/BKappa2006/DSC00873.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/DSC00886.jpg)
Nice and straight!
(http://i53.photobucket.com/albums/g61/BKappa2006/DSC00884.jpg)
Possibly the heart of a future project GS500GoKart?
Time to prep the 93's frame for paint! .........to be continued.
I see beemer wheels, an R1, and an air cooled four...looks like a GS 850...spiffy.
you're 2 for 3. That is an R1....My roommates ridiculous 2007. and that is an aircooled 4 cylinder, but its actually an 1100, out of a 1984 Kawasaki 1100LTD, which is pretty much just wasting space in my garage. The motors good, but it came out of an unregisterable frame. Lastly, you're close with the rims. They are off of a german car, just not a bmw.
I've been ridic. busy lately, but finally got some free time to work on the bike. Decided I was going to mock up my new subframe on the parts frame, and then transfer it over to the good frame once its finalized. So I went at the damaged subframe with my cutoff wheel....
(http://i53.photobucket.com/albums/g61/BKappa2006/DSC00959.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/DSC00960.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/DSC00958.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/DSC00957.jpg)
and heres a very rough sketch of the subframe design I'm going for. I'm going to be using 1" by 1" square steel tubing.
(http://i53.photobucket.com/albums/g61/BKappa2006/DSC00963.jpg)
and another look at the damaged subframe....
(http://i53.photobucket.com/albums/g61/BKappa2006/DSC00961.jpg)
Keep it coming, keep it coming.
This is exactly what I needed to see! Be sure to take lots of pics and be as detailed as you can be. Make sure to be detailed about the frame and how you paint it. :D
Very nifty. I'm not a fan of the docked-tail look, but I appreciate a well-done project.
Today, I started work on the new subframe. Started off by grinding down the gs frame to accept the 1" square tubing. Then I positioned both 2 foot sections of tubing onto the frame...
(http://i53.photobucket.com/albums/g61/BKappa2006/DSC00964.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/DSC00966.jpg)
Now it's time for the two supports for the main tubes. Simply mocked it up, cut the basic angles I needed, and shaped with the grinder to get it perfect. Then tacked it in place.....
(http://i53.photobucket.com/albums/g61/BKappa2006/DSC00967.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/DSC00969.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/DSC00970.jpg)
Now the hard part....making a matching support for the other side. But it ended up being easier than the first side was. And here's how I left her today.......
(http://i53.photobucket.com/albums/g61/BKappa2006/DSC00971.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/DSC00973.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/DSC00974.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/DSC00975.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/DSC00976.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/DSC00977.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/DSC00978.jpg)
to be continued....
:cheers: :cheers: :cheers: :cheers: :cheers: :cheers: :cheers: :cheers: :cheers: :cheers: :cheers: :cheers: :cheers:
outstanding work, keep the pictures coming! I think it will look awesome once finished. heck it looks cool now!
great thread. keep us posted! :thumb:
oh gosh, i'm addicted to this build. Can't wait to see more progress on the project.
OK so you hacked off the straight frame :dunno_white: ...
Then you're fitting the new style seat onto the rails you are welding on ...
You see, there is a better way to fit that seat on the old frame, I did it several years ago to cheesy/se7enty7's bike which he sold later to Tarzanboy.
I dunno, what is your final goal, cos you're not throwing on the R6 or GSXR tail like the others do, not that I am a big fan of that ...
Cool.
Buddha.
Looks like this is gonna be sweet.
Props for the effort, and for those asking why he's cutting a perfectly good frame when he could have done the same thing to the old one. I would have to say clean title. I wouldnt have worried about it personally, I would have done it all on a salvaged frame, but regardless cant wait to see it done.
Thanks for all of the feeback everyone. and Chanse you are correct. The original gs I had was totaled. and to get that registered, I would have had to either...have a licensed salvage repair shop repair the bike and document all receipts ect (very expensive), or attempt to clean the title in another state (ie. sell the bike to a friend out of state, fix it, and have them register it, then finally sell it back....paaaain in the ass) So instead, I bought another gs with what was thought to be a blown motor, but had a clean title. I was originally going to just swap everything over to the good frame and call it a day. But then I started looking around customfighters.com....... and I decided to go all out and design my own custom gs. I've been meaning to do a project like this for a while, and now finally have the opportunity.
Thats great! :)
With that 1 inch sqaure bar, does the original gs fram slide into that? or is that a welded butt joint? i may doing something similar. not for bent frame but for looks. Also in the future I will need to know hos to make my own seat for previously said project.
The 1" square tubing slides over the gs frame, after you grind down the paint. Its a tight fit height wise, but width there's extra room, since the frame isn't made from perfect square tubing. I'll be building up the gs frame on the sides to make the fit even tighter, to ensure no side to side play. As for the seat, I'll be using a one off of a 2007 R1.
Work faster!!! I want to see the final product. Sounds like it's going to be pretty cool.
With the little free time I had this weekend, I did manage to get some work done, and received a few things in the mail as well.
Now that I know the angles of my subframe are going to work when the bikes assembled, its time to get the good frame ready for the swap. I made identical cuts, removed the unnecessary brackets, and cleaned up the mating surfaces.
(http://i53.photobucket.com/albums/g61/BKappa2006/DSC00982.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/DSC00985.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/DSC00983.jpg)
Now if everything goes as planned, I should have the subframe on the this frame by wed. and can start fab'in some cross braces.
I also disassembled my 2 bro's can....
(http://i53.photobucket.com/albums/g61/BKappa2006/DSC00981.jpg)
All ready to be chopped.
and finally, some new parts.....
(http://i53.photobucket.com/albums/g61/BKappa2006/DSC00980.jpg)
2006 R6 rear shock
(http://i53.photobucket.com/albums/g61/BKappa2006/DSC00988.jpg)
drag bars
(http://i53.photobucket.com/albums/g61/BKappa2006/DSC00989.jpg)
2007 R1 taillight
(http://i53.photobucket.com/albums/g61/BKappa2006/DSC00986.jpg)
and some new gel grips
Hoping to have the frame completed by the end of the week. Then its on to the tail fairing.
Today I finalized the rear subframe and welded it to my frame. Came out perfect. Now all I need to do is weld the cross braces in and then I'll be able to finish weld the frame and grind it down smooth. Then off to powdercoating!
(http://i53.photobucket.com/albums/g61/BKappa2006/DSC00998.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/DSC00997.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/DSC00996.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/DSC00995.jpg)
and just a cool action shot
(http://i53.photobucket.com/albums/g61/BKappa2006/DSC00999.jpg)
Warning - boring old fart Safety diatribe - may upset immortal youngsters.
Learn how to dress for welding from TV?
(http://i53.photobucket.com/albums/g61/BKappa2006/DSC00999.jpg)
I guess you have a helmet on, which is more that half the TV idiots who pretend to weld do.
That hood is a good way to catch sparks. Will warm the back of your head if they get cozy and burn.
The "sunburn" your arms get may come back to haunt you later in life.
Welding, like motorcycling, is a good place for lots of leather - or at least tightly woven flame-resistant cotton. Try a cape sleeve and bib if you find a jacket too hot. And actual welding gloves - you're wearing rubber gloves by the look of it???
I know I know....but I didn't feel the need to put a leather jacket on when I was just throwing down some tack welds. and I forgot my leather gloves at work today which I def regretted. Latex gloves don't block hot embers very well... oh well. chicks dig scars right?
yea you dont need a leather jacket who cares. and besides if your spendin all your time indoors welding, you gotta get tan somehow, why not get tan by weldin.
As my friend Paul loves to say, and to put on his truck, "LIFES SHORT, WELD NAKED!"
Quote from: gregvhen on October 14, 2009, 09:43:01 PM
"LIFES SHORT, WELD NAKED!"
Well, that's certainly one way to make sure that life is short, and painful. Of course, skin cancer only happens to other people...
Quote from: kappa2006 on October 14, 2009, 08:24:38 PM
I forgot my leather gloves at work
Basic welding gloves are certainly cheap enough to have a pair at work and a pair at home.
http://store.weldingdepot.com/cgi/weldingdepot/102112.html (http://store.weldingdepot.com/cgi/weldingdepot/102112.html)
Quote from: kappa2006 on October 14, 2009, 08:24:38 PM
Latex gloves don't block hot embers very well... oh well. chicks dig scars right?
I think that only applies to large cuts and bullet holes. Little burn marks all over your body doesn't have quite the same appeal..
lesson learned......moving on
Well its been a week and progress has been slow. But.... its starting to come along. Finished up welding the subframe and cleaned up the welds. Also welded in supports for my solo seat.
(http://i53.photobucket.com/albums/g61/BKappa2006/GS500/DSC01005.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/GS500/DSC01002.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/GS500/DSC01020.jpg)
Took a 2007 Yamaha R1's seat....
(http://i53.photobucket.com/albums/g61/BKappa2006/GS500/DSC01007.jpg)
pulled the leather covering off...
(http://i53.photobucket.com/albums/g61/BKappa2006/GS500/DSC01008.jpg)
and "modified" the plastic base to fit my subframe and to wrap tightly around my tank...
(http://i53.photobucket.com/albums/g61/BKappa2006/GS500/DSC01009.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/GS500/DSC01010.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/GS500/DSC01011.jpg)
Next I wanted to mock up the rear swinger / R6 rear shock combo to make sure everything was a go...
(http://i53.photobucket.com/albums/g61/BKappa2006/GS500/DSC01013.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/GS500/DSC01012.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/GS500/DSC01016.jpg)
Also decided to ditch my previous plan of chopping my 2 bro's can to use for my undertail. Instead.....
(http://i53.photobucket.com/albums/g61/BKappa2006/GS500/DSC01017.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/GS500/DSC01019.jpg)
One of the 2 cans from...you guessed it. 2007 R1. I think once its chopped down by about 4", it should flow nicely with the tail.
To be continued....
just one thing... Thats gonna look sick. :woohoo:
It's gonna be interesting to see how this turns out :thumb:
I need to weld more...
Am liking the subframe idea. Might have to pinch it to fit the SV650 tail.
Nice, I love all these tail conversions. I need a damn welder!!!! :woohoo:
Since my last post, I finally finished up the subframe. I ended up changing the design a bit after seeing it finished. But I'm happy with it now. Also got the battery box mounts fabbed up (sealed gel battery) I started my tail fairing mold too. I purchased a sheet of insulation from lowes (1" by 1' by 8' for $8), and some spray adhesive (regretting not going with 3M because the cheap stuff is eating away at the foam). I started by cutting pieces and stacking them together to make a block. Then I mounting it to the frame. Once that was done.....I started getting the basic shape I wanted. Still very far from being complete, but its coming along. So far I've been focusing on the side profile of the rear section of the tail, and I already have about 4 hours into it so far. So the front of the tail fairing is NOT shaped yet, except for where the seat meets the fairing.
Also, my Katana rear wheel came in the other day!
One thing I've noticed....I'm slowly drifting away from my initial plan. Oh well. Thinking about ditching the undertail exhaust now and mounting duals down low, parallel to the ground in front of the rear wheel. we'll see...
(http://i53.photobucket.com/albums/g61/BKappa2006/GS500/DSC01185.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/GS500/DSC01187.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/GS500/DSC01191.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/GS500/DSC01189.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/GS500/DSC01190.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/GS500/DSC01207.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/GS500/DSC01208.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/GS500/DSC01206.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/GS500/DSC01209.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/GS500/DSC01203.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/GS500/DSC01205.jpg)
Wauw! Awesome work. Very well done. :bowdown:
I'm looking forward to see how the final result turns out.
your not really just using a 110v flex core welder for something thats going to see street time are you
I'm using a 115v mig welder w/ solid wire, and I sleived the joints between the subframe and the frame. Also, I did several tests on scrap 1" square tubing to get the voltage and wire feed speed perfect, giving me the proper penetration. The rear portion of the subframe won't be supporting any weight other than the tail fairing and taillight. I'm confident that the subframe will be more than strong enough to support my weight.
You mean Flux core Josh....And welding with flux core would be strong enough if welded correctly- welding wire flux core is uglier and leaves slag and requires cleaning the welds after and is not as good as MIG... As Kappa said.... it's all about the right penetration in the weld.
Kappa- you using CO2/Argon ? Didn't see a bottle near your welder.
Looks Good Kappa.... for your next foam adventure- they sell glue for styro-foam at most kraft stores if it melts too much for your needs.
I'm using argon. and thanks for the tip on the foam adhesive. Will definately go that route next time.
Thanks for all the comments!
Nice project.
One thing though i think you should change, is the angle of the rear fairing from the seat. like right behind the seat the foam is too vertical needs to be cut at an angle a little more. For my liking anyway, just my .02.
(http://i966.photobucket.com/albums/ae150/gregvhen/DSC01203.jpg)
Question: when you make the rear faring final, do you cover that foam in fiberglass cloth, and resin? or are you just using the foam for a mold and removing it after youve made the plastic part?
After the foam mold is finished, I plan on first attempting to cover the mold with foil and then fiberglassing over that. Then the mold should release from the foberglass fairing easily. But if the foil doesn't cover the tail properly, I'll just glass over the foam, and then remove the foam by dissolving with gasoline or something similar. Hoping the foil method works out so I can save the mold for another tail....just in case.
As for the tail design, I'm still far from being finished with the shape. I won't be leaving the area behind the seat like that. Just haven't gotten to that part yet. It will definately be cut down, and sloped up to the rear.
if you carve out the inside and glass it too and put a lid on it you could have a built in beer cooler :thumb:
haha. you might be on to something there..... :cheers:
Foil is a good idea, i used packaging tape and it worked fairly well. The fiberglass resin WILL melt the foam if not covered or painted with house paint or celephane wrap or some release agent,lookin' good. Good Luck !
I dont like the adhesive tape idea the resin tends to react with the plastic or the glue, foil works ok but if you dont use a wax or something as a releasing agent some of the foil will get imbedded into the glass.
thanks for the suggestions.... think I'll start by trying foil...maybe sprayed with a little pam or similar releasing agent. No biggy if a little foil sticks to the underside of the tail.
Did more work on the tail today. I'm happy with how its coming out. Opinions? Suggestions? I know its kind of hard to see all of the angles with the light, but you can get a decent idea of how its looking.....
(http://i53.photobucket.com/albums/g61/BKappa2006/GS500/DSC01229.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/GS500/DSC01231.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/GS500/DSC01228.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/GS500/DSC01219.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/GS500/DSC01218.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/GS500/DSC01210.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/GS500/DSC01217.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/GS500/DSC01224.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/GS500/DSC01222.jpg)
While on a ride on the weekend I got talking to a guy on a GSXR. He had one seat and a cowl. Said he could remove the cowl and replace the seat for his wife to ride with him, or if he sells. The cowl was hollow. So he said he bought a Lid from a boat supply place, cut a hole in the bottom of the cowl to allow access into the hollow cavity, and installed the screwable lid. Looked like this
(http://a1672.g.akamai.net/7/1672/116/20091101/www.ritzcamera.com/graphics/products/m-63/large/MP80814063_bg.jpg)
I think they are called Deck Plates
Michael
Ok......any other feedback? haha
Thanks for the update. I'm really curious how that rear end turns out. I might try something like that myself, if you are successfull!
Keep up the good work!
Quote from: joshr08 on November 19, 2009, 10:23:43 AM
if you carve out the inside and glass it too and put a lid on it you could have a built in beer cooler :thumb:
Or evewn better . . . . AN AQUARIUM!!!! :thumb:
(http://i53.photobucket.com/albums/g61/BKappa2006/GS500/DSC01228.jpg)
Kinda looks like...
(http://www.sacramento365.com/images/event/40823/gold_king_tut.jpg)
There's your paint scheme.
Quote from: DoD#i on November 25, 2009, 09:08:27 PM
(http://i53.photobucket.com/albums/g61/BKappa2006/GS500/DSC01228.jpg)
Kinda looks like...
(http://www.sacramento365.com/images/event/40823/gold_king_tut.jpg)
There's your paint scheme.
I totally see it
Well I wasn't happy with the tail....so I decided to cut some more. Running out of foam here! I'm happier with this new shape....at least for the moment. Doesn't seem as blocky as the last. Opinions?????
(http://i53.photobucket.com/albums/g61/BKappa2006/GS500/DSC01239.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/GS500/DSC01240.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/GS500/DSC01241.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/GS500/DSC01243.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/GS500/DSC01244.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/GS500/DSC01247.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/GS500/DSC01248.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/GS500/DSC01249.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/GS500/DSC01256.jpg)
the tail is angled too high in my opinion now, and some more material under the rear section would clean up the lines real well too. This project is awesome, i hope to make a cafe style tail for my bike one of these days, now that I read your thread i have an idea about where to to start lol. Good work, keep it up :thumb:
there are 3 other layers (about 3" total) of foam that go on the bottom of the tail section and will hide the frame. The glue kind of sucked and those sections fell off. But right before I glass, I'll resecure them back onto the tail.
As for the angle of the tail itself, that's the look I'm going for. Kind of a streetfighter look to it. The overall shape of the tail itself is what I'm not 100% sure on yet. Its getting there though.
Thanks for the comments!
I think the tail is perfect now. Don't make it smaller!
I've always liked having a flat back for solo seats where the part just behind the seat would rise rather steeply, and then the bike lines are formed from there.
(http://www.streetfighters.com.au/forum/upload/52115927768846.jpg)
(http://i53.photobucket.com/albums/g61/BKappa2006/GS500/DSC01249.jpg)
Looks a little bit off-center or non-symmetrical to my eye. I think the angle of the photo is good - the shock appears to line up with the steering stem, so it's straight behind. You can strike a centerline and cut templates for something more precise than "take a little off here, take a little off there, whoops it's disappeared" - make the template fit one side, flip it and see where it indicates the other side is high (or low, but then you'll need to figure a way to fill the low spots).
Its definately a pain in the butt trying to get the tail perfectly symetrical. The "take a little off here and there" method got me pretty close, but making a template like you suggested should help get it even closer.
I don't like it...the end is too high and angled wrong. The tail should be parallel to the top of the tank, in my opinion, and I really prefer them to share the same plane.
Quote from: makenzie71 on December 31, 2009, 09:29:49 AM
I don't like it...the end is too high and angled wrong. The tail should be parallel to the top of the tank, in my opinion, and I really prefer them to share the same plane.
Have to agree about the tail/tank plane.
Overall I like it, but is it just going to be the frame, with a small tail and all that subframe sticking out? I think it would work well if you extended something down along the sides under the seat to tie it all together.