I figured I'd start a new thread documenting the entire assembly process with pictures. This thread will be far from a proper assembly tutorial, and I'm sure it will illustrate some improper techniques and hardships, but hey, looking at pictures is cool....
Here the motor and areas of the frame are taped up, I also ground down the powder coating on the frame engine mount ears to aid in fit...
(http://inlinethumb32.webshots.com/47455/2605246170073478356S600x600Q85.jpg)
(http://inlinethumb11.webshots.com/46794/2551774920073478356S600x600Q85.jpg)
Here the motor is finally installed, hopefully it won't need to come out again, matter of fact, it WON'T be coming out again...
(http://inlinethumb31.webshots.com/12254/2545922920073478356S600x600Q85.jpg)
(http://inlinethumb10.webshots.com/8585/2356093360073478356S600x600Q85.jpg)
Tomorrow the Swingarm and Shock will be assembled and mounted, more pics to follow.
isn't it difficult to remove the blue tape after everything? Or do you take it off as you go along?
Quote from: ragecage23 on October 09, 2010, 10:52:52 AM
isn't it difficult to remove the blue tape after everything? Or do you take it off as you go along?
It can be, but I make sure the tape is in areas where it doesn't get pinched between the 2 items I'm trying to protect...Most of the tape will stay on until most of the assembly is finished, ya never know when your gonna drop, bang, or scratch something, so it's a bit of added insurance. Keep in mind though, this is far from a show bike quality, very far from that as my abilities, income, and impatiences just don't allow for it.
Well get with it would you!
Just curious, did you paint the motor with high temp paint? Until it's properly cured, it may come off in little flakes with the tape.
And an old garden hose or foam pipe insulation wrapped around the frame and taped in place will protect the finish while taking the motor out or putting it back in the frame.
Looks good so far though!
Quote from: Big Rich on October 10, 2010, 01:22:38 AM
Just curious, did you paint the motor with high temp paint? Until it's properly cured, it may come off in little flakes with the tape.
And an old garden hose or foam pipe insulation wrapped around the frame and taped in place will protect the finish while taking the motor out or putting it back in the frame.
Looks good so far though!
Yes, the motor was painted with Dupli Color 1200 degree Engine Matte Black, was cured in a 90 degree garage for like 4 hours, and has sat for over a year all bagged up waiting for me to get off of my lazy arse and start building this thing, it's held up quiet nicely.
Hey Fry, can you show how you mounted the mesh on the subframe?
Quote from: centuryghost on October 10, 2010, 07:10:23 AM
Hey Fry, can you show how you mounted the mesh on the subframe?
The mesh is used in commercial grade loud speakers, I have it in big 3'x3' sections and just cut out a cardboard template of the area I went to inset it in, lay that cardboard over the mesh, spray paint around it, then use a cut off wheel to cut out the piece. I then Mig weld it in from behind. I was going to put a nice thin bead of seam sealer around the outside, visible edge but now that everything is coated it looks ok, slight gaps and variations aren't all that visible. I also mad a tray out of this stuff to relocate all of the wiring, relays and electronics under the seat.
(http://inlinethumb64.webshots.com/40191/2687202340073478356S600x600Q85.jpg)
I screwed this one up (Upper right corner) but you get the idea, once pressed in there I tac/welded it from behind.
(http://inlinethumb29.webshots.com/40092/2920971820073478356S600x600Q85.jpg)
Electrics tray
(http://inlinethumb41.webshots.com/34216/2066343850073478356S600x600Q85.jpg)
(http://inlinethumb58.webshots.com/42361/2580643600073478356S600x600Q85.jpg)
(http://inlinethumb35.webshots.com/40546/2161685050073478356S600x600Q85.jpg)
(http://inlinethumb49.webshots.com/43184/2840829070073478356S600x600Q85.jpg)
Pretty cool Yankee Ingenuity. Gives a unique look for sure. So how much more time you figure you have left on assembly?
Quote from: JB848 on October 10, 2010, 05:10:27 PM
Pretty cool Yankee Ingenuity. Gives a unique look for sure. So how much more time you figure you have left on assembly?
Thanks....
I spent the day with these so I didn't get much done today, just installed all new bearings and spacers in the Swing Arm and installed it on the bike. Next I need to detail the shock and install that.
Guns, Yummy.
(http://inlinethumb24.webshots.com/44503/2220812920073478356S600x600Q85.jpg)
(http://inlinethumb33.webshots.com/45280/2833908570073478356S600x600Q85.jpg)
I felt guilty spending the day at the range, least I got something done on the bike today.
(http://inlinethumb56.webshots.com/6519/2793810560073478356S600x600Q85.jpg)
(http://inlinethumb57.webshots.com/43704/2632942090073478356S600x600Q85.jpg)
Probably about another 2 months before I try and start it, probably 4-5 months before it's fully assembled and 100%...
BS do it quick and do it now...more pictures please?
Got alot done on the bike today, got the Side Covers On, Valve Cover, New Clutch and Springs put in, New Crank Seal installed, Lubed every with the clutch acctuator, installed a new clutch cable, basically installed all the shiny new powder coated pieces, all new gaskets, seals and such.
Not home tonight but I took lots of pics and will post them up tomorrow.
Next on the docket is to install steering head bearings and races, triple trees and get the forks on, hopefully I'll get that done tomorrow.
As promised here are the recent pics...
Cam/Valve Cover Installed, had to do it twice, 1st time I forgot to put the cam chain buffer on the bottom side, Doh!!!
(http://inlinethumb01.webshots.com/33664/2578455610073478356S600x600Q85.jpg)
New Clutch and associated hardware installed, crank seal installed and greased, and cover put on for good.
(http://inlinethumb13.webshots.com/45324/2113033010073478356S600x600Q85.jpg)
Hope all of this is correct? Made sure the crank pin engaged/locked into the middle piece, hopefully the timing isn't messed up, nothing else was touched in the timing/valve train.
(http://inlinethumb56.webshots.com/47607/2773102430073478356S600x600Q85.jpg)
All buttoned up, I wont be buying the Suzuki Round Sticker for the front of the side cover.
(http://inlinethumb03.webshots.com/44418/2801094530073478356S600x600Q85.jpg)
I found these little round metal disc's in my garage that I will do something with..
(http://inlinethumb35.webshots.com/45986/2345786610073478356S600x600Q85.jpg)
(http://inlinethumb25.webshots.com/9304/2374608140073478356S600x600Q85.jpg)
(http://inlinethumb58.webshots.com/46265/2456756860073478356S600x600Q85.jpg)
Clutch Actuator all cleaned and greased, with the mystery ball bearing re-inserted...
(http://inlinethumb04.webshots.com/36867/2904266610073478356S600x600Q85.jpg)
Going through it's range of motion, testing it out to make sure I had it fitted correctly...
(http://inlinethumb46.webshots.com/47533/2233129090073478356S600x600Q85.jpg)
(http://inlinethumb23.webshots.com/33302/2918421000073478356S600x600Q85.jpg)
This next picture is causing me great anxiety and I won't know for sure until much further down the road...These 3 bolts for the Stator went in very hard, and the 3rd 1 in got stripped/cross threaded somehow, this is the furthest it will go down, and it was very hard getting it to this point. All 3 have loctite on them, and the other 2 are really tight, possibly cross threaded themselves as well. I'm thinking there might have been sand in the threads from sand blasting the covers, and it F'ed up when I ham fisted them in. There is no movement in the part, and test fitting it reveals? that the raised screw head doesn't hit anything once bolted up to the motor, hopefully I wont run into issues with this? I know it's really hack, but I would have ended up really creating a ton of work trying to get it out of there, I'd have to travel to my Brothers to get metric taps, it would have been a mess, just keeping my fingers crossed at this point, feedback please on this potential causing an issue.
(http://inlinethumb23.webshots.com/45590/2687078290073478356S600x600Q85.jpg)
Shifter side all buttoned up, new clutch cable installed. I'll will be using the metal discs to use on this side as well instead of the factory Suzuki emblem.
(http://inlinethumb49.webshots.com/46320/2527493110073478356S600x600Q85.jpg)
Cylinder and Head un-tapped, I like the look.
(http://inlinethumb55.webshots.com/47094/2780699360073478356S600x600Q85.jpg)
(http://inlinethumb56.webshots.com/45815/2844285480073478356S600x600Q85.jpg)
(http://inlinethumb49.webshots.com/7600/2832484990073478356S600x600Q85.jpg)
(http://inlinethumb58.webshots.com/42681/2163977180073478356S600x600Q85.jpg)
I'm gonna try and get the Triple Clamps and new steering tube bearings installed today, perhaps even the forks though I still need to paint the legs of the forks.
Well, I was able to get most of what I wanted to do today, done. Got the new Steering Bearings and Races installed. Got to adjust the pre-load and attach the top clamp and associated hardware, it looks good, and went together smoothly.
New Bearings, Powder Coated Lower Clamp. Took some Emery cloth and really cleaned up the bearing surfaces getting rid of rust, corrosion and powder coating on the bearing seats. Also sanded the holes were the forks come through, there was a bit of an edge with the PC'ing.
(http://inlinethumb32.webshots.com/45855/2310017020073478356S600x600Q85.jpg)
There was a lot of baked on Sand from the Sand Blasting/Powder Coating Process so I cleaned these areas out with a die grinder/wire wheel combo.
(http://inlinethumb39.webshots.com/45350/2369245310073478356S600x600Q85.jpg)
(http://inlinethumb13.webshots.com/44620/2422282070073478356S600x600Q85.jpg)
No that ain't blood on the towel, LOL....
(http://inlinethumb55.webshots.com/21174/2326848240073478356S600x600Q85.jpg)
(http://inlinethumb17.webshots.com/46416/2033750860073478356S600x600Q85.jpg)
(http://inlinethumb33.webshots.com/46176/2234137560073478356S600x600Q85.jpg)
Bearings packed, everything cleaned and lubed waiting for assembly.
(http://inlinethumb09.webshots.com/1928/2668759330073478356S600x600Q85.jpg)
Top Race put in.
(http://inlinethumb38.webshots.com/39333/2139710680073478356S600x600Q85.jpg)
Bottom Race installed.
(http://inlinethumb46.webshots.com/47533/2324617530073478356S600x600Q85.jpg)
Lower Bearing installed.
(http://inlinethumb61.webshots.com/44028/2100810970073478356S600x600Q85.jpg)
Loosely fitted.
(http://inlinethumb27.webshots.com/45402/2829377230073478356S600x600Q85.jpg)
(http://inlinethumb28.webshots.com/4635/2970391410073478356S600x600Q85.jpg)
Loosely fitted, I like the contrasting of the 2 top clamps.
(http://inlinethumb46.webshots.com/47725/2397681570073478356S600x600Q85.jpg)
(http://inlinethumb15.webshots.com/46286/2479639830073478356S600x600Q85.jpg)
Time to watch some football, probably will go out to the garage later tonight and get the fork lowers prepped for paint, finish setting the pre-load on the bearings, and final assemble all of the Triple Clamps and associated parts and hardware. It's getting close to being a roller again.
Decided to do a bit more work. Cleaned and assembled the Gauges, Dash Panel/Bezel and mounted it. I may take off the Middle Triple Clamp as it's gloss Black paint is faded and hazed and though looks OK IMHO after cleaning, it would look better with a quick, fresh coat of Flat Black.
Here are the latest pics...
(http://inlinethumb12.webshots.com/45387/2008109310073478356S600x600Q85.jpg)
(http://inlinethumb03.webshots.com/44994/2607767270073478356S600x600Q85.jpg)
(http://inlinethumb49.webshots.com/22512/2340876370073478356S600x600Q85.jpg)
(http://inlinethumb36.webshots.com/35427/2588844400073478356S600x600Q85.jpg)
(http://inlinethumb21.webshots.com/44692/2696763550073478356S600x600Q85.jpg)
(http://inlinethumb30.webshots.com/31645/2776180250073478356S600x600Q85.jpg)
(http://inlinethumb59.webshots.com/44858/2936621110073478356S600x600Q85.jpg)
(http://inlinethumb14.webshots.com/42381/2418263810073478356S600x600Q85.jpg)
(http://inlinethumb31.webshots.com/25118/2219998900073478356S600x600Q85.jpg)
Got a bit more done today. Painted the Fork Lowers, Painted the Shock Cushion Lever, and cleaned the Shock. Got most of the rear suspension done only hold up was a missing Cushion Bolt, had to order a new one. Got the Forks Installed as well. Also touched up the wheels as the got a few scrapes on them, I painted them like 2+ years ago, sitting in my garage un protected gave them a few nicks...
Shock Cushion Lever quickly painted.
(http://inlinethumb33.webshots.com/44576/2038980760073478356S600x600Q85.jpg)
Wheels touched up.
(http://inlinethumb51.webshots.com/46002/2111181620073478356S600x600Q85.jpg)
Forks Primed, then painted a Satin Black.
(http://inlinethumb37.webshots.com/27364/2300817230073478356S600x600Q85.jpg)
(http://inlinethumb44.webshots.com/47467/2760357590073478356S600x600Q85.jpg)
(http://inlinethumb17.webshots.com/46672/2625156870073478356S600x600Q85.jpg)
(http://inlinethumb49.webshots.com/8112/2230275480073478356S600x600Q85.jpg)
(http://inlinethumb07.webshots.com/44742/2322922080073478356S600x600Q85.jpg)
Well, that all for now, probably for this week until I get some parts in....
Wow! Fry everything look beautiful. I am surprised you painted the forks after all of the detail you put into your project. By they look very nice besides the point.
Can't wait to see the rolling chassis!
About 2 years ago I rebuilt the Forks and was so far away from painting/finish options, I just assembled them and put them aside. I should have had the lowers Powder Coated as well yet at the time I had no clue and I was not pulling them apart again or waiting 2 weeks for them to get powder coated, so I took a risk with a rattle can and got good results, color and texture wise there not an exact match, but it looks acceptable.
I was so methodical with labeling and bagging all the parts and bolts I'm really pissed and at a loss for where 1 of the 3 Rear Cushion Lever Bolts could be, it's the only thing that held me up today, otherwise the rear would have been final assembled and Trq'd to spec. I should get a discount at Ron Ayers with all the little odds and ends I've been ordering of late.
I need to clean, paint and detail the Discs, Clean Paint and Detail the Calipers and M/C, for the mounting of the wheels, that's this weeks/weekends goal, get the tires on it and make it a roller.
The seat isn't going to sit that high is it? It'll sink with the weight of you + the bike, right?
Quote from: ragecage23 on October 18, 2010, 07:33:14 PM
The seat isn't going to sit that high is it? It'll sink with the weight of you + the bike, right?
It isn't seatd into its mounts in the pics, and I have to shave the bottom side of it a bit to get it right...
Did some mocking up of the Handle Bars, Headlights and Directionals, all just a loose fit for now. Once I get everything aligned and finalized I will take it apart, paint it (Flat Black), bundle and wire tie all wires into a single plastic wire tube and move onto the next area.
The Stock Frt. Directionals are far to wide with their stalks and I contemplated for a few on how to cut them down to no avail.
I then found these lying around my garage, there Rear Directionals that came off of my Brothers HD.
(http://inlinethumb35.webshots.com/47906/2496469970073478356S600x600Q85.jpg)
Took them apart and found that I could mount them onto the headlight bracket easily, both on the inside and out side, I think I'm going to mount them on the outside.
(http://inlinethumb50.webshots.com/37169/2478904930073478356S600x600Q85.jpg)
(http://inlinethumb48.webshots.com/23407/2811813930073478356S600x600Q85.jpg)
(http://inlinethumb58.webshots.com/47929/2477026190073478356S600x600Q85.jpg)
Inside the Headlight bracket, this is more compact, but I don't like the look.
(http://inlinethumb02.webshots.com/44801/2433038930073478356S600x600Q85.jpg)
Here are the Pro-Taper Fat Bars, MX Pastrana Low Bend. They will need to be cut down obviously, just a test fit.
(http://inlinethumb25.webshots.com/47064/2474379770073478356S600x600Q85.jpg)
(http://inlinethumb07.webshots.com/47174/2105586830073478356S600x600Q85.jpg)
(http://inlinethumb55.webshots.com/29366/2805631480073478356S600x600Q85.jpg)
(http://inlinethumb11.webshots.com/44042/2210563010073478356S600x600Q85.jpg)
Test fitting the Bar End Mirrors, there pretty cheap, we'll see how long they last. They hopefully will look better once the bar is cut down.
(http://inlinethumb59.webshots.com/44154/2135825680073478356S600x600Q85.jpg)
(http://inlinethumb50.webshots.com/4273/2762506510073478356S600x600Q85.jpg)
(http://inlinethumb34.webshots.com/46945/2924286020073478356S600x600Q85.jpg)
(http://inlinethumb48.webshots.com/45935/2829925410073478356S600x600Q85.jpg)
More to follow...
Its coming along nicely.. Cant wait to see the finished product
Looking good Fry..put those flippin wheels on LMAO :thumb:
Quote from: JB848 on October 22, 2010, 09:07:48 PM
Looking good Fry..put those flippin wheels on LMAO :thumb:
I'm having issues....With the wheels....Well, with painting the little plastic ring that goes around the inner portion of the front rim...Adhesion Promoter, sanding, nothing helps, ARG!!!! Plus The bench it's on is stresses right now, the wheels will stay off until the very end.
Here's a question for you guys...The Stk Frt. Directionals have 2 wires coming out of them a Blk and a Blk/Wht one I think, these new ones only have 1 wire, how do I connect them? Do I make a common Ground? Will it effect the directional operation?
It depends how they mount. If it's to a metal bracket, then they should be ok.
The one wire should go to the hot (+12v) on the old harness. As Rich said, if the new blinkers mount directly to metal, you should be OK. This provides the ground (the other wire's purpose). If you don't have a good metal/metal contact - on top of powdercoat won't work - you can run the second wire to a mounting bolt to provide the ground.
The mount onto the Stk Headlight bracket, which has been painted, yet not powder coated. The Blinkers themselves have a metal hollow barrel and corresponding hollow bolt (To allow wire to run through) that mount be sandwiching the headlight brackets. I will clean all of the paint off of the mounting areas, and a touch of dialectic grease and mount them up wiring each one to the hot 12v lead of the headlight harness.
Thanks guys.
The stock indicators need two leads because the stems are made from a flexible plastic that doesnt conduct electricity and as such cant provide a ground to the frame through its fixing.
Single lead indicators are designed to ground out to the frame via the indicators own fixings. As long as its not being attached to a part of the bike that is electricaly isolated from the frame like a plastic or fibreglass fairing or headlamp cowl it should work fine. Even if the indicator had to be fixed this way the solution is realtively easy in that you would have to run a ground cable to the bolt or fixing that holds the indicator.
I've painted both my front wheels of my bike and never had an issue. All I did was make sure they were clean with mineral spirits and they took paint just fine. What issue are you having?
(http://www.bayarearidersforum.com/forums/images/threads/000/121/937/1833649-worthless.gif)
The wheels/rims took the paint fine, it's that little 5" round plastic trip piece that I think goes over the are where the ODO goes...Paint kept bubbling up, had to soak it in boiling hot soapy water, scuff it, then hit with Adhesion Promoter (twice) before it took the paint without issue. Pics later.
Quote from: Fry on October 24, 2010, 02:34:47 PM
The wheels/rims took the paint fine, it's that little 5" round plastic trip piece that I think goes over the are where the ODO goes...Paint kept bubbling up, had to soak it in boiling hot soapy water, scuff it, then hit with Adhesion Promoter (twice) before it took the paint without issue. Pics later.
Yes that piece gave me issues too when I painted my wheels. Luckily it was small and could be redone. One thing with painted wheels is that it's so tough keeping them form chipping. I put about 6 layers of rattle can flat black and clear on them and occasionally I still get chips from road debris. I switch wheels colors from red to flat black because when my wheels were red i would use touch paint to fill in the chip holes but it was hard to hide red touch up. The flat black touch blends in much better.
your gonna be cutting those bars some, id bet almost anything before you decide its comfortable. i had long dirt bars like that too for a little while. they where good for wheelies cause standin up theyre a perfect angle, but for rockin around normal riding i hated the manuverability, or lack there of. just a heads up :thumb:
I'm cutting about an inch of each side....We shall see if there OK, I don't mind a bi of pain and maneuverability issues. Or I might find a way to give them some pull back, might just shave off the lower handle bar clamps, and be able to use the plethora of HD bars and Risers out there....Time will tell. Thanks for the feedback
I'm not looking anymore until you get the wheels on >:( Do you want me to tell you how I painted my rims? :dunno_black:
Quote from: JB848 on October 26, 2010, 09:31:31 PM
I'm not looking anymore until you get the wheels on >:( Do you want me to tell you how I painted my rims? :dunno_black:
No, I dont want you to tell me...My rims are painted, new bearings installed, there set to go, it ws the plastic odo trim piece that was giving me issues, but is now painted and ready to go....
The wheels are going on last....If only to piss you off further. Ok, if I get really motivated this weekend, Ill get the wheels on.
Luckily I did the Kat FE swap so that piece made way for a second rotor.
Cool
looking good.
LOL Fry I can't wait she is looking real good though with all the parts you have been showing us :thumb:
Anyway I was going to tell you what I used and it worked the first time paint the plastic odometer ring...I wiped it down with a generous amount of Mineral Spirits and I had no issue with bubbling. I have also had good luck using rubbing alcohol with a longer drying period.
Prior to using the adhesion promoter, scuffing, and hot soapy water bath, I tried a healthy cleaning with Mineral spirts, didn't work...I tried that process like 2-3 times with horrible results...Adhesion promoter did the trick....
After today, I have the next 11 days off, and though I have some customer work coming in, I plan on getting a lot done, and yes I plan on getting the wheels on.
I hope my over posting of pics doesnt upset or seem like Im bragging? I know what I am and am not creating, I know my abilities and lack therefore of, and know the are tons out there that are better....Just sharing the experience.
I can't speak for everyone but the pictures make the process more interesing for me. Keep the pictures small like you have and only because a lot of people use the forum from their BlackBerries and such, a little warning in the title (Pic Heavy) is common practice. :thumb:
Quote from: Fry on October 29, 2010, 03:17:53 AM
I hope my over posting of pics doesn't upset or seem like I'm bragging? I know what I am and am not creating, I know my abilities and lack therefore of, and know the are tons out there that are better....Just sharing the experience.
What you are doing is very creative. cosmiccharlie, O.C.D and others have been doing similar projects for a long time and have inspired many to do their own project and avoid mistakes and pitfalls.
So from me...Thanks for sharing your experience
life is more fun with pictures and sound effects.
to be honest, I could go with less of your talking and more picture..
jk :) it all looks good! love the progress. I gotta hit some parts of my GS with a coat of paint for sure.
Quote from: EdChen on October 29, 2010, 02:37:26 PM
to be honest, I could go with less of your talking
I hear that a lot, LOL....
Well, I got a few more things done, assembly is really moving along.
Painted and Baked the Disc Centers.
(http://inlinethumb10.webshots.com/9/2565585510073478356S600x600Q85.jpg)
Cleaned Rear Wheel hardware.
(http://inlinethumb33.webshots.com/47776/2728290860073478356S600x600Q85.jpg)
Cut the Handlebar width down, drilled holes to mount Switch housings.
(http://inlinethumb25.webshots.com/2136/2517639450073478356S600x600Q85.jpg)
Rear Wheel mounted.
(http://inlinethumb27.webshots.com/46362/2429117640073478356S600x600Q85.jpg)
(http://inlinethumb52.webshots.com/45043/2329029600073478356S600x600Q85.jpg)
Front Wheel prepped for install.
(http://inlinethumb13.webshots.com/45900/2163081610073478356S600x600Q85.jpg)
(http://inlinethumb63.webshots.com/46974/2909608700073478356S600x600Q85.jpg)
(http://inlinethumb56.webshots.com/4471/2269207800073478356S600x600Q85.jpg)
(http://inlinethumb40.webshots.com/47783/2705303140073478356S600x600Q85.jpg)
With wheels on it's only moments away from being rolled on her own 2 wheels this hasn't been possible in a long time. It's starting to look like a bike again, and overall I am happy with the results.
(http://inlinethumb09.webshots.com/41736/2945890560073478356S600x600Q85.jpg)
(http://inlinethumb45.webshots.com/46700/2494855780073478356S600x600Q85.jpg)
(http://inlinethumb42.webshots.com/46953/2360129010073478356S600x600Q85.jpg)
The Light of Day, she hasn't been in the sun for a while.
(http://inlinethumb38.webshots.com/43621/2523764320073478356S600x600Q85.jpg)
(http://inlinethumb13.webshots.com/47692/2497075800073478356S600x600Q85.jpg)
(http://inlinethumb29.webshots.com/37468/2604069380073478356S600x600Q85.jpg)
Mocking up the seat and tank, I really am liking the overall design of the bike and it seems to be unified, without anyone thing drawing your attention, not that theres much of anything crazy going on, on the bike I'm just pleased with the cohesiveness of it all.
(http://inlinethumb52.webshots.com/26355/2831580550073478356S600x600Q85.jpg)
(http://inlinethumb39.webshots.com/17382/2928853640073478356S600x600Q85.jpg)
(http://inlinethumb40.webshots.com/231/2721080900073478356S600x600Q85.jpg)
(http://inlinethumb57.webshots.com/20664/2070951940073478356S600x600Q85.jpg)
(http://inlinethumb17.webshots.com/45776/2511898410073478356S600x600Q85.jpg)
Calipers need to be prepped and painted, all other brake hardware cleaned, then mounted. Peg mounts need to be cleaned, prepped painted, and mounted. Headlight and Directionals need to be installed, Exhaust needs to be hung. Carbs need to be re-jetted and mounted for new exhaust. Wiring harness needs to be cleaned, detailed, installed, and cleverly routed. Then the decision on what to do with the tank needs to be made. All of this, and probably a billion other little things need to get down before start up, maybe soooon.
Boy you're almost there. She is looking better and better. Love the blacked out front rotor :thumb:. What were they thinking with that gold at the factory? They must have had a lot of paint left over or something.
The disc center was Black from the factory? Or did I replace it at some point in it's life? Is the stk. disc center gold from the factory?
looks good,but I say take off the tach and speedo, who needs gauges anyway hahaha
Quote from: Fry on November 03, 2010, 06:23:58 AM
The disc center was Black from the factory? Or did I replace it at some point in it's life? Is the stk. disc center gold from the factory?
I think they ran out of paint in 1994. But yes they were gold :icon_eek:!
Quote from: Fry on November 03, 2010, 06:23:58 AM
The disc center was Black from the factory? Or did I replace it at some point in it's life? Is the stk. disc center gold from the factory?
just looked at my 93 and the center of the front is gold, the center of the back is black.
Quote from: JB848 on November 03, 2010, 07:24:16 AM
Quote from: Fry on November 03, 2010, 06:23:58 AM
The disc center was Black from the factory? Or did I replace it at some point in it's life? Is the stk. disc center gold from the factory?
I think they ran out of paint in 1994. But yes they were gold :icon_eek:!
must have been my bike in 93.
Only a bit of progress today...
Brake Calipers ready for assembly.
(http://inlinethumb45.webshots.com/45740/2463826840073478356S600x600Q85.jpg)
Floating Caliper Mount greased up.
(http://inlinethumb44.webshots.com/3435/2358931370073478356S600x600Q85.jpg)
Seals and Pistons installed.
(http://inlinethumb47.webshots.com/4142/2098906340073478356S600x600Q85.jpg)
Pads, Shims and retainers installed.
(http://inlinethumb40.webshots.com/45735/2601687380073478356S600x600Q85.jpg)
Mounted
(http://inlinethumb60.webshots.com/44475/2322319170073478356S600x600Q85.jpg)
Rear ready to be mounted.
(http://inlinethumb53.webshots.com/30580/2553076140073478356S600x600Q85.jpg)
Mounted
(http://inlinethumb19.webshots.com/44626/2130476650073478356S600x600Q85.jpg)
Dirty Peg Assemblies.
(http://inlinethumb41.webshots.com/9192/2398061790073478356S600x600Q85.jpg)
Dis assembled awaiting cleaning and finishing options.
(http://inlinethumb12.webshots.com/44363/2795245260073478356S600x600Q85.jpg)
Cleaned and ready for Powder Coating and assembly.
(http://inlinethumb36.webshots.com/35811/2786985070073478356S600x600Q85.jpg)
I'm going to have the brackets that mount to the frame PC'ed Anthracite, the same as the wheels and side covers. The Shifter, and Brake Pedal will be coated in the Rough Matte Black PC'ing that the frame was coated in. The Heel Guards will be PC'ed the same color as I get the tank done. I'm kind of leaning towards a really heavy metal flake Suzuki Blue for the tank with flat black in the knee cut outs, thus the only other blue on the bike will be the heel guards.
Is that original pegs just without a rubber, or aftermarkets? :o
Those are aftermarket pegs...
I have to say Great Job....
Have you hung the exhaust cans and sat on it since you made it a roller? I'm curious if it will bottom out with the suspension travel...
Thought about mounting a bandit 400 hugger? Have to see one on it I guess ...
Again....looks good.
Quote from: Jared on November 05, 2010, 08:24:32 AM
Thought about mounting a bandit 400 hugger?
Just bid on 1 on Flea Bay.....I was going to try and mod the Stk. GS500's fender arrangement but realize this is money well spent.
I think you should paint your front caliper gold to be retro and authentic..err yeah right!
Um, Yeah NOT....
IMHO Calipers should mostly be Black....Only time I like to see Painted or Colored Calipers is when they have the abilities of these....
(http://www.gtrblog.com/wp-content/uploads/2009/07/alcon-oe-brakes-540x406.jpg)
(http://www.historicmotorsports.com.mo/shop/images/120-8080RSR.jpg)
(http://wp-content.rpmware.com/wp-content/uploads/2009/12/4-GTR-Top-580x368.jpg)
Err I meant rotors sorry..but then again red rotors might start a trend?
A hugger will probably look nice and clean on there....
So have you mounted the exhaust up and sat on the bike yet ?
Ohh and never ever feel bad for spending time at the range ( 1 or 2 pages back )...
Bike looks good...very good.
A hugger oh my! Would that be a plug for Airbrush?
Quote from: JB848 on November 05, 2010, 10:12:20 PM
A hugger oh my! Would that be a plug for Airbrush?
I have no idea what you mean by this?
Anyway, looks like I just scored a Tire Hugger, in my home State no less, for $20 bucks, NICE....
Quote from: Fry on November 06, 2010, 07:04:56 AM
Quote from: JB848 on November 05, 2010, 10:12:20 PM
A hugger oh my! Would that be a plug for Airbrush?
I have no idea what you mean by this?
I believe he is referring to a guy on here that makes them. I only recall this because his entire bike was airbrushed, and looks super bad-ass.
Quote from: Fry on November 06, 2010, 07:04:56 AM
Quote from: JB848 on November 05, 2010, 10:12:20 PM
A hugger oh my! Would that be a plug for Airbrush?
I have no idea what you mean by this?
Anyway, looks like I just scored a Tire Hugger, in my home State no less, for $20 bucks, NICE....
Nice! what kind did you get? Ive been thinkin of putting a hugger on my bike..
1 from a Bandit 400, think I read somewhere on this site that it will fit....If it doesn't, I will make it.
Thats the right additude!!
A bit of an update....Still haven't gotten the hugger to fit, look like I want, might end up doing a super minimal one out of a front fender blank, who knows though.
I know Its been a while since I last worked on or posted anything about the GS Street Fighter but with the winter gone, and the snow melted I'm back out in the garage, making slow progress.
Here is a bit of an update of the items I got done during the last few months or so, yes it's been a slow process.
The last update ended with me trying to make the heel guards look cool. I managed to finish them, and got the foot pegs, guards, rear brake pedal, master cylinder, and reservoir mounted.
In this pic the heel gaurd inserts are in place, and are painted, same color (Almost) as the wheels and side covers.
(http://inlinethumb05.webshots.com/47364/2190659050073478356S600x600Q85.jpg)
Here are the foot peg mounts painted, a semi gloss black to match the Frame.
(http://inlinethumb47.webshots.com/45550/2123499480073478356S600x600Q85.jpg)
Brake side controls mounted.
(http://inlinethumb24.webshots.com/46167/2421065440073478356S600x600Q85.jpg)
Shifter side mounted.
(http://inlinethumb61.webshots.com/47164/2976436380073478356S600x600Q85.jpg)
With the fold away passenger foot pegs, and homemade rear subframe I needed to figure out a way to mount and hide the Rear Brake Reservoir so it didn't clutter the look of the bike or interfere with the PAss pegs in either the up or down position.
I had to shorten the line going from the Reservoir to the Master Cylinder and rotate the line a bit, once that was done I was able to tuck the reservoir up and under the seat to the mesh panel/electronics trays underside with a tidy bracket with flush mounting hardware.
(http://inlinethumb30.webshots.com/46301/2763104940073478356S600x600Q85.jpg)
Passenger pegs folded down and out, totally clearing the brake line.
(http://inlinethumb43.webshots.com/46890/2342511760073478356S600x600Q85.jpg)
(http://inlinethumb14.webshots.com/31181/2755770970073478356S600x600Q85.jpg)
Today was a productive day out in the Garage. The Exhaust system initially did not fit correctly as well as being to close to the lower frame rails and oil pan. I discovered this when mocking the system up to see if I needed a heat shield of sorts. I have no idea what occurred to make the system as far off as it was, but after a few hours out in the garage with a Chop Saw, Welder, and Grinder every thing mounts up perfectly, level and there is plenty of room between the top of the Silencers and the bottom of the Oil Pan. Everything looks symmetrical and level. All I have to do now is re-paint the header tube portions with DEI Ceramic (1400 degree) paint that I welded and ground on, then re wrap with the exhaust wrapping, install the exhaust pipe/head donut gaskets and remount everything one last time.
Here I have the bike hung to be in a better working position.
(http://inlinethumb27.webshots.com/45594/2130755060073478356S600x600Q85.jpg)
Next I cut the down tubes after they bend coming out of the head. Once both pipes were cut I then bolted up the 2 Elbow shaped portions that fit into the head, then I bolted up the 2 Silencer and pipe combos to the under engine mounts. This left me with about and inch or so gap in the down tubes that I needed to fill. I cut a 2" length of 1 1/2" I.D. exhaust tubing to use as a sleeve over the existing exhaust tubes, filling in the inch gap, in this pic you can see the sleeves not in their final position.
(http://inlinethumb05.webshots.com/45764/2862097120073478356S600x600Q85.jpg)
In this pic the sleeves are slid upwards covering the gap made by cutting and fitting the entire system.
(http://inlinethumb54.webshots.com/48117/2208497450073478356S600x600Q85.jpg)
Tacked into place, yes it looks like bird shaZam!.
(http://inlinethumb04.webshots.com/45443/2142030710073478356S600x600Q85.jpg)
Once tacked into place I removed each system and welded and ground them fully on the bench and remounted each one.
(http://inlinethumb58.webshots.com/44985/2235854600073478356S600x600Q85.jpg)
Everything fits perfect now, in this pic your looking from the front of the bike back at the under engine mount. Both Silencers are level and low and behold are far enough away from the oil pan for me not to worry about a heat shield.
(http://inlinethumb04.webshots.com/47747/2247352260073478356S600x600Q85.jpg)
With the bike back on the ground and everything solidly mounted I am pleased with the results. They sit flush, level, and are seemingly symmetrical from every angle, just as I initially intended.
(http://inlinethumb07.webshots.com/45830/2589618050073478356S600x600Q85.jpg)
(http://inlinethumb17.webshots.com/24720/2634826540073478356S600x600Q85.jpg)
(http://inlinethumb17.webshots.com/45584/2777768530073478356S600x600Q85.jpg)
(http://inlinethumb30.webshots.com/48605/2691699910073478356S600x600Q85.jpg)
(http://inlinethumb31.webshots.com/45278/2064045030073478356S600x600Q85.jpg)
Here are a few up to date shots of the bike during this final assembly.
(http://inlinethumb51.webshots.com/47922/2894480870073478356S600x600Q85.jpg)
(http://inlinethumb21.webshots.com/44884/2124375060073478356S600x600Q85.jpg)
(http://inlinethumb01.webshots.com/47488/2941940180073478356S600x600Q85.jpg)
Well, that's it for today, once I re-paint and re-wrap these pipes I will start on getting the carbs rebuilt, jetted, and mounted along with the lunch box K+N air filter. Also have to order some S.S. brake lines, mount them and bleed the brakes.
I'm sure I'll run into a ton more little fitment issue and other little nagging problems, but I'm getting closer.
great job. I like the attention to detail. Exhaust mounts are pretty cool.
HOT HOT! I love the black. Are those superbike bars? Once done remember to post a sound clip of the exhaust!
Great job on that exhaust, llloving it.
Fry, any thoughts on the effect your exhaust system will have on the jetting? Was there theory put in place to keep jetting stock or are you just going to worry about that once you are done fabbing this up?
Quote from: utgunslinger13 on April 26, 2011, 11:51:18 AM
Fry, any thoughts on the effect your exhaust system will have on the jetting? Was there theory put in place to keep jetting stock or are you just going to worry about that once you are done fabbing this up?
Oh, Im going to do a lot more than worry about the exhaust once finished assembling the bike....I'm going to Swear, Yell, Rant and Rave, Spill Gallons of Gas swapping jets and making adjustments, make small sacrafices to the moto gods, see a team of highly paid therapists, and then and only then, hope to get it rideable. SEAMAX has been helpful with suggestions on jetting and though I've contacted Buddah a few times on parts/spare jets however I think I will just do trial and error. The bike was re-jetted (By ME) with a Factory Stage 3(?) kit for the complete Hinson system that I installed, and though it was lean on decel it was driveable, maybe, just maybe the jetting for that will work for this exhaust, probably not though. ANyone who wants to add suggestions on EXACTLY what jets and what tuning, Id appreciate it.
Thanks SEAMAX, I wouldn't think you'd like BLACK, LOL....
Quote from: seamax on April 26, 2011, 07:39:00 AM
Are those superbike bars?
Here are the Bars, Pro-Taper Fat Bars, MX Pastrana Low Bend. In this pic they weren't cut down to the correct width, just test fitting them at that stage.
(http://inlinethumb25.webshots.com/47064/2474379770073478356S600x600Q85.jpg)
Well I got a bit more work done today, just a few little things.
I mounted an electrical box to the back side of the Battery Box.
(http://inlinethumb64.webshots.com/46719/2547817470073478356S600x600Q85.jpg)
Relocated the Fuel Petcock. I used these style fasteners to leave a flush area on the mesh as I will be mounting more electrical components there.
(http://inlinethumb08.webshots.com/519/2635026330073478356S600x600Q85.jpg)
(http://inlinethumb07.webshots.com/44934/2445927660073478356S600x600Q85.jpg)
Bent up a little bracket to hold the Petcock.
(http://inlinethumb09.webshots.com/46024/2231880570073478356S600x600Q85.jpg)
(http://inlinethumb32.webshots.com/46815/2903324970073478356S600x600Q85.jpg)
Painted and Mounted the Brake Tq. Arm. Installed the R. HEL SS Brake Line.
(http://inlinethumb59.webshots.com/46330/2384862340073478356S600x600Q85.jpg)
Still have to cut and install the F. Lines....And about a billion other things...
gotta be careful about you fuel level with the petcock out of reach.
bike looks great.
Quote from: reload on May 09, 2011, 07:20:19 AM
gotta be careful about you fuel level with the petcock out of reach.
bike looks great.
Style (SUBJECTIVE) over Function.
Quote from: Fry on May 09, 2011, 07:29:16 AM
Style (SUBJECTIVE) over Function.
yeh, that's a tough one :technical:. it just wouldn't look nice with a petcock sticking out of the frame, esp on your custom build.
Thanks SEAMAX, I wouldn't think you'd like BLACK, LOL....
[/quote]
LOL, wait 'till you see the color on my cafe build.
Is that like a textured black because I see little dimples?
Yes Seamax, it is a textured Powder Coat black, forgot the exact name/color. I could have went with a smooth finish but I thought the textured look gave it some character and such....
How about a sneak preview of the Cafe project?