Hail Lemmy!!! :bowdown:
No doubt you guessed I'm a Motörhead fan.
I'm third generation biker from the south west UK. My old mans still riding and my gramps was still riding at the good age of 80 after spending his years after the war as an AA patrol man on a Norton sidecar outfit. Im a carpenter by trade, old mans an engineer and taught me to weld, bend tube etc and I've been creating my one off's ever since out of anything I can get hold of.
I'm picking up a GS500 slingshot at the end of the month and I'm stuck for ideas of what to do with it. I would say I'll tart it up a bit, ride it and love it but who am I kidding, that'll never happen. I cant help but meddle and cut stuff up., I'm a serial motorbike abuser with an angle grinder and noise problem.
I love the parallel twin engine for its simplicity as with the singles. I'm planning on using most of the bike for a hardtail custom to put a lot of miles on. Not exactly conventional I know but having seen a couple and having some free time on my hands in the evenings since departing from the other half I'm going to blast this one out in time for summer. How far I take it is yet unsolved but I'm sure it'll come to me as soon as its on the lift.
So heres a couple of pics of previous projects, the orange one was turned around in month of evenings in January 2014, originally a Honda CM 125 copy converted to a 150cc with uprated carb, sprockets, ports polished etc... The Yamaha came to me as a dodgy runner, completely bodged to pieces and would run for more than five miles before dieing and refusing to start as well as most of the electrics where shot.
(http://i65.tinypic.com/2z8t1sj.jpg)
(http://i63.tinypic.com/2rw9a54.jpg)
(http://i68.tinypic.com/qxkm4i.jpg)
With a fullish build here
Nice first post pattman!! Glad to have ya here on the board and can't wait to see what ya do with a GS :cheers:
yep, looking forward to seeing where your gs journey winds as well pattman :thumb:
Hey pattman, check out Phil Campbell and the Bastard Sons, if you haven't already. He's plucked his sons out of their respective bands and they've been touring and recording lately.
Any ideas for the Suzuki yet?
Chris
O0
Cheers for the welcome :thumb:
Whats the carbs like to work on these bikes and could they handle minimally baffled exhausts? If they are anything like the abortions Yamaha decided to put on the Virago range I'll be really tempted to swap them out for a pair of Mikuni VM34's or a single VM38 on a dual feed manifold for their sheer simplicity and reliability.
I've got a few ideas floating around, the lack of a metal lathe at the moment somewhat limits the extent of parts I can make though. I'll more than likely try and keep the front cradle of the frame if possible and rework the back end. I'll have to check dimensions and seating position once I've got it home as to how much will need to go. The orange bike was really cramped, being just over 6'3" and 15 stone you could say a clown on a monkey bike but the Yam was just right. Don't want the foot controls to far out in front as it doesn't help with the rain going up your legs or the stretched out position for hitting any pot holes with no support for my dodgy back. Not sure what style of tank to use or possible make although I do have a weird shaped mustang tank sat in the corner being neglected which needs to be made a lot bigger, its friggin tiny!
I've got a run planned in late May to Wales so hopefully the bike will be finished to an extent and sorted with shakedown runs before hand so if I loose anything I can make a replacement. I've only lost a battery cover and a seat bolt so far so haven't done to bad.
So three months of evenings and a couple of weekends I haven't got my nippers to get it sorted. Now for colour choice. I always loved the purple with gold pin striping my old man had on his GS850, now rocking around on a Suzuki Intruder trike.
(http://i61.tinypic.com/2a9zbds.jpg)
Might say the GS bug was caught from a young age.
(http://i66.tinypic.com/ddbyna.jpg)
ooooo I like that purple and gold as well. Those rims remind me of Chrysler rims... I like that too!
Does anyone know if the cast 5 spoke wheels from the early GS range are a direct replacement or do the bearing need to be changed? Thinking of the end look, may get a pair and powder coat them.
Well, I've been let down as the the bike is now no longer available after we already struck a deal :flipoff: Nice. So I'm on the lookout for another one to play with. Project currently on hold which sucks.
Finally sorted a GS500. FSH, new MOT, 16k on the clock, 53 reg for a monkey, and it was less than a mile down the road.
Going to put a few hundred miles on it first to get a feel for the engine then it'll be chop time. :woohoo:
Considered going to VM34's myself. They should work fine .
Cool looking stable of past projects. Best of luck in the quest for a GS
Now I have a dilemma. I've never really been into street bikes, always customs, but the bike I picked up is a minter and its solid engine performance has grown on me so I don't want to chop it, so I picked up a right shitter of a bike to chop instead for next to nothing. So I'm thinking of keeping the GS and tricking it up a bit.
So, what to do to it... I'm thinking air filter and end can for now as I'll be using it to commute. Recommendations of cans and filters with jets to suit?
Quote from: pattman on June 03, 2017, 12:16:36 PM
Now I have a dilemma. I've never really been into street bikes, always customs, but the bike I picked up is a minter and its solid engine performance has grown on me so I don't want to chop it, so I picked up a right shitter of a bike to chop instead for next to nothing. So I'm thinking of keeping the GS and tricking it up a bit.
So, what to do to it... I'm thinking air filter and end can for now as I'll be using it to commute. Recommendations of cans and filters with jets to suit?
Good call. I was getting ready to boycott this thread forever.
OK airfilter - the stock paper one can be washed and reused, and otherwise replacing it every 6-8K costs $10 or so, its an expense I've come to tolerate. The GS lasts a whole lot longer with that paper filter kept clean over anything else.
I would do a nice slip on or even a good full system, and jet it to breathe right and call it a day. I make up kits to jet for K&N etc etc, but I run the stock air filter, and I in fact have a new one sitting on the shelf waiting to go in (maybe early next week). For the exhaust I'm running a Titanium Yosh tri oval pipe on stock headers.
Cool.
Buddha.
How much did the slingshot go for and how did it look? Was it a private sale or was it advertised? Where in the UK are you?
88/89 were the years they branded GS5s as slingshots in the UK. F and G reg and very very rare now. I am presently looking for a semj-decent one with original paint and graphics and the all important cast suspension knuckle as a resto' project. I have got contacts all over the country looking for one for me but it just isn't happening!!!
Don't anybody ever chop a slingshot, they will be worth something..........one day!!
And if someone sees one in the UK PM me.......quick!!!
Slingshot was an 89, wasn't mint by any means and was advertised for £895 in the midlands. Settled on a price but it was sold before I could get the deposit sent.
Still running my GS stock, I've put 1500 miles on it, tops out at 105ish mph.
The bike I bought for chopping wasn't worth it so I picked up a GS500 frame from a breakers that was written off, salvaged the headstock as the frame was twisted, rear end impact. Going to build a hardtail frame as a direct replacement for the original to literally bolt everything on to and back if required so keeping the original frame intact and unmolested.
Cheers for the info Buddha, looking into exhausts depending what I do.
Quote from: sledge on June 04, 2017, 01:54:17 PM
How much did the slingshot go for and how did it look? Was it a private sale or was it advertised? Where in the UK are you?
88/89 were the years they branded GS5s as slingshots in the UK. F and G reg and very very rare now. I am presently looking for a semj-decent one with original paint and graphics and the all important cast suspension knuckle as a resto' project. I have got contacts all over the country looking for one for me but it just isn't happening!!!
Don't anybody ever chop a slingshot, they will be worth something..........one day!!
And if someone sees one in the UK PM me.......quick!!!
gonna buy a slingshot from the UK, and chop it all up now. lets see... maybe a dirtbike mod? :icon_lol:
With nitrous?
Aaron
So, the story so far.... not a lot.
I've made the bench, well top of it
(http://i66.tinypic.com/2ue65bc.jpg)
And a height adjustable neck holder to keep everything straight and true
(http://i64.tinypic.com/103fk7a.jpg)
Some tapered neck supports
(http://i65.tinypic.com/32ztdsp.jpg)
And fitted ready to build
(http://i68.tinypic.com/xwuom.jpg)
And one of me from a local bike night in aid of the Royal British Legion
(http://i68.tinypic.com/15efdow.jpg)
And one from last year on my previous project, same bike night
(http://i64.tinypic.com/10yp8jl.jpg)
All being well I might actually get started properly at some point
Well, finally the bench is up, axle plates made and jig is in place. Bench has been laser levelled in and bolted down so all measurements can be taken of off it for reference and making sure everything is true and straight. Heights have all be worked out, 6" from bottom rails to ground as the exhausts are going to be run under the frame and side exiting through a muffler box. The heights of the axle plates and headstock have been lowered accordingly so the bench is at frame rail height so everything can sit straight on it. Everything has been centred so it should be plain sailing, hopefully.
All the steel is here for the frame and I've got some sheet steel waiting to be made into a fuel tank and battery box etc. Need to find or make a seat, headlight, electric box, fuse holder, fenders and sissy bar for camping gear as well as deciding on the handlebars, seat height... but its build time, at last. And of course, the pics.
(http://i68.tinypic.com/qq1kld.jpg)
(http://i65.tinypic.com/2e4g6ys.jpg)
(http://i65.tinypic.com/2dwdoas.jpg)
Went for a ride to the last RBL bike night of the year, was a good turn out. Had fun dodging the goats and now deer chucked in the mix through the gorge on the way home....
Front down tube notched, tacked, straightened and welded, lower rails bent and notched to the down tube ready for rear ends to be bent and notched for the axle plates. All good fun.
(http://i68.tinypic.com/14b8ao4.jpg)
(http://i65.tinypic.com/ruxl3b.jpg)
(http://i63.tinypic.com/8xvkb8.jpg)
(http://i63.tinypic.com/htv76c.jpg)
good stuff here! :bowdown:
Cheers dude, totally winging it :cheers:
Carrying on, blasting out rock and blues in the garage, had an epiphany of what to do with the top tube.... I didn't really, it sounded good though. Formers worked ok with a bit of brute force keeping it straight. Need to come up with a name for it now, its getting to the point where it should have one. Bits of sh*t welded together just doesn't really have the ring to it. Anyway, pictures and more pictures.
Frame rails cut, notched and channelled for the down tube and axle plates
(http://i65.tinypic.com/23u5wz6.jpg)
I worked a length of tubing through a ring roller making the constant curve, offered up before notching
(http://i68.tinypic.com/2zexxyb.jpg)
After notching and tacked
(http://i63.tinypic.com/21cyoh1.jpg)
(http://i66.tinypic.com/vql1ua.jpg)
Welded in with a crossmember taking the end to the frame rails, i'll gusset this later on to make sure the bastard is solid
(http://i64.tinypic.com/x42jwx.jpg)
With a cross member to keep the shape and deter distortion, also gives a nice shape for the fuel tank I'll make later on. The lower rail is on a backwards fall so giving the tank a natural flow to the right place. Forward thinking or what!
(http://i67.tinypic.com/243l2te.jpg)
The rear frame rails will be something like this. I'm planing on taking the seat down as far as possible so your low to the ground but as the bike will only be roughly 400mm wide and 6" off the ground, leaning through the corner will be easy, hopefully.
(http://i65.tinypic.com/66x1n6.jpg)
I'm liking where this bike is going and the shape its taking, probably the best looking one so far. I want to change the wheels though, looking at Kawasaki 8-9 spoke mag wheels instead of the three spoke things, I'll see how it looks when they are on, with good tyres its purely for looks.
Neat!!! I'm certainly watching :D :popcorn:
Great imagination and workmanship--I'm really curious about the gas tank.
Nice quiet weekend rocking out in the garage building a bike frame, bliss. *Frame is all but complete, some brackets / gussets*(oh matron!) to make and weld in, engine mounts, exhaust mounts, tank mounts, battery box, electrics box, rear brake torsion arm and loads of other stuff I've probably forgotten.
Rear wheel is in for now, need to make some cross members for the mud guard to fix to and figure out where the indicators and associated cables are running. *I've got a plan for the brake light to make it a bit different but inconspicuous.... now thats got you thinking hasn't it....
Rear frame rails cut and welded in place, cross members yet to go in
(http://i63.tinypic.com/243hxzm.jpg)
GS getting dismantled. *Now the problem here is that the exhaust studs are nakerd, big time. *Looks like its weld a nut on the end and try to get them out that way but the heads are rusted to crap and falling apart. *May drill them out and try the lock nut approach on the studs.
(http://i66.tinypic.com/293hdo4.jpg)
Rear wheel in and spaced roughly enough with what I had to hand. *Think I'll be going for either straight bars or mini Z bars depending if I get them made or I make them.
(http://i63.tinypic.com/n1ukut.jpg)
Had to have a go making bike noises, its compulsory you know, everyones got to make a twat out of them selves at some point and I'm the master.
(http://i63.tinypic.com/10okweu.jpg)
Great progress pics! Can't wait to see what this bike looks like when its done.
My fav thread right now,...sweee-eet. Bliss on a weekend in the garage fook yes (http://www.motohouston.com/forums/images/smilies/headbang.gif)
Holy sheet, this looks like it could be one of the best gs builds out there.
Keep it cominG!
definitely not my cup of tea but F**K i can appreciate the work you're putting in, good stuff man, cant wait to see how it turns out :thumb: :cheers:
Good stuff here, excited to see it continue :cheers:
Three hours. Three f*****g hours to get two exhaust headers off thanks to two rusted bolts rounding off then sheering off and having to be drilled out. But they are off and the engine can come out at last. Just as well I'm making a new pair from the header back as the mid section is rusted to hell and fell apart when I took it off literally snapping in half leaving me with end can in one hand, headers in the other and pile of rust on my shoes.
When the engines out I can get it aligned with the rear wheel, mounts made and bolted in, petrol tank can be mocked up with loads of cardboard, electrics box etc etc, the list goes on and on...... but tomorrow its the weekend, van shopping first, needs must, and then back to building stuff and making a mess with loads of Motörhead. Absolute epic bliss.
Small update. Been busy with my business with the run up to Christmas so haven't had a lot of free time to get on with the build. I've managed an odd couple of hours here and there, mainly trying to remove a snapped engine mount bolt. Resulting in hours of shouting at it, welding on nuts, blow torching, squirting penetrating oil like a teenager with a porn mag and the good old fashioned drill the fecker out.
(http://i66.tinypic.com/1fcmyg.jpg)
(http://i63.tinypic.com/531kpv.jpg)
And the end result
(http://i67.tinypic.com/145phd.jpg)
But I did manage to align and mount the engine, just the top rear engine mount to sort out which will have to be removable for the engine to come out.
(http://i67.tinypic.com/21pmc7.jpg)
Soon to start on mocking up the exhausts and templating for the fuel tank.
squirting penetrating oil like a teenager with a porn mag lol
Aaron
sorry for your frustration :technical: but lovin the progress
How do you plan to get a tank to fit in that odd curve ? Or you making your own ?
If you did, I'd call it an umbrella tank - or umbrella bike for that matter.
BTW, hard mounted rear wheels beat the hell out of axle bolts and the holes for the axles in the frame. You probably need to have some sort of suspension - and no not just a seat spring. Remember as heavy as you could be, the bike still out weighs you by say 2X.
Cool.
Buddha.
I'll be making a tank to suit the frame, worked it out to hold near enough 14-14.5 litre / 3.1 gallon. Should see me far enough in-between stations for refilling without having to worry about running dry. Definitely not going the peanut tank for 60 mile range as seems to be the dumbass trend in the custom world.
I plan to solid mount the seat but haven't worked that one out yet. I'll more than likely make it from dense foam to suit the frame and seating position and have it upholstered. I did run the old chop solid mount for 18 months and only fitted springs when I sold it for a wider target market - it was sold within a day from listing on the net.
I am really eager to see your tank. I appreciate the high quality of your workmanship.
Manifolds. Every bike needs them and being an awkward sort of muppet I am in using a single VM38 I needed to make one.before fabing the rear engine mount. My pipe bender crinkles the hell out of thin wall pipe so I ordered a couple of mandrel 45 bends from 42.5 x 1.5 steel tubing and where delivered the next day before Christmas but I've been either to pissed, to stuffed or building lego with my kids to go out to the garage. I think I had more fun than they did, parents prerogative.
So, I marked it out on the bench as a plan so I could keep everything near enough parallel and its easier to mark the cut lines.
(http://i66.tinypic.com/35c226o.jpg)
Aforementioned bend
(http://i63.tinypic.com/1zmmf81.jpg)
Bend met the angle grinder
(http://i63.tinypic.com/33zeib9.jpg)
And the other bend felt left out so I chopped his ass off too
(http://i67.tinypic.com/5n2etk.jpg)
Part welded ready for the inlet tube
(http://i63.tinypic.com/rs8xvl.jpg)
Inlet tube tacked and soon to be shortened to suit
(http://i64.tinypic.com/29fq9vl.jpg)
The tubing is slightly bigger than the original carb outlet so I stuck the rubber manifolds on the lathe and the internal ridge down to suit the tubing
(http://i66.tinypic.com/21b2lqh.jpg)
Manifold plate for the VM to bolt to
(http://i68.tinypic.com/23seubl.jpg)
Plate welded to the manifold
(http://i66.tinypic.com/jugx0i.jpg)
Carb bolted on and mounted to the bike
(http://i66.tinypic.com/10ncdjn.jpg)
(http://i67.tinypic.com/2iky33c.jpg)
(http://i68.tinypic.com/kbde9d.jpg)
The carb has a choke lever assembly (enricher rather than a choke but same principle - ha, for once I almost sounded like I know what I'm on about) built into it so theres no need for a choke cable, the carb cable will be running into the carb via a 90 bend to miss the tank and not screw the cable and as the carb has an internal slide spring there is no need for a return cable. Now thats out the way its the rear engine mount then frame is almost done bar a couple of gussets, foot pegs and side stand. As soon as thats done the forks can go on and fab up for exhausts can begin.
Finally, the pain in the ass top rear mount is fabbed and fitted apart from a couple of gussets.
Made some sleeves for the bolts through the frame
(http://i66.tinypic.com/24b67hu.jpg)
(http://i64.tinypic.com/2dvptgo.jpg)
Now the sleeves come into use
(http://i67.tinypic.com/2r3zb01.jpg)
(http://i67.tinypic.com/vebx2c.jpg)
Welded and fitted
(http://i64.tinypic.com/r2iwyd.jpg)
(http://i64.tinypic.com/20z4kgh.jpg)
Now what to do next on the massive list of stuff to do....
Got the forks off the old bike and onto the new frame to decide on a number of parts I need to make and what I can't make and need to order. Mainly to decide on the seating position and foot peg position.
Theres a choice of two foot positions really. Either
(http://i64.tinypic.com/20huhdl.jpg)
Or like this
(http://i66.tinypic.com/2ilumd.jpg)
The way the gear rotation works with the box means the foot control will need to be on a double joint if I use fowards so it'll need a bearing mount as well as a new clamp for the gear shaft, but it was the most comfortable position. I need to get the mudguard sorted as that pretty much dictates what size seat, shape of seat and how it gets mounted - either solid or sprung.
Fuel tank and new cables for the clutch and throttle to make, electrics to alter, handlebars to either make or buy depending on the style and price, electrics box, battery tray or box, coil housing, indicators, sissy bar for carrying gear to rallies, the list goes on and then theres the paint; sprayed or powder coat, colour, finish....
Totally cool! I am really curious to see how the single carb works.
So am I, its a to easier to work with than the original carbs and doesn't suffer from the usual cross wind stutter / hesitation without the air box.
As per usual, when you actually need to go to the suppliers its a bank holiday and they're shut. I still haven't replaced the front engine mount bolt that corroded itself in there and needing it to keep the engine steady whilst I move the bike around I had to run one down from a high tensile M16 bolt that I seem to have in abundance... haven't a clue where they came from but I've got loads of them in the cupboard.
If you've got the room I really recommend a lathe. I really don't know how I managed without it apart from bodging the crap out of stuff. Next on the list is a milling machine but sitting pretty at a grand it can wait a bit longer.
(http://i64.tinypic.com/6zae04.jpg)
Now everything is held in place its now sitting pretty on the bench as it would be on the road. Still deciding on the seat position....
(http://i67.tinypic.com/35jcmxt.jpg)
Has anyone got any recommendations as to where I can buy a chain? The normal places don't stock anything long enough, unless I buy two and bodge it with two slip joints.
bad asssss
why cant you buy two chains with the clip style master links, and just hack em together like that? or if your fond of riveting... two riveted ones. its how the custom bicycle guy's do their weird stuff... however for as many 520 chains out there on GSXR750's STRETCHED A MILE LONG. - there should be some long enough for your project.
ask a gixxer guy, they should point you towards the bike shop, that points you towards the supplier...
- yeah I take stabs at gixxer guys too. :D
Well, as with all good plans I didn't get as much time as I thought. But I've got the tank sorted apart from the fuel tap is 1/2" BSP not metric and being a sunday nowhere is open to pick a tap up. I ordered a couple of taps so it should be here sometime soon to finish it off and pressure test it.
The many uses of cardboard packaging, cheers amazon.
(http://i65.tinypic.com/vsdiqs.jpg)
(http://i64.tinypic.com/nl7qr4.jpg)
Welded the seams on the inside as well as the outside so shouldn't have a problem with it holding pressure and not leaking.
Trial fit.
(http://i68.tinypic.com/aze7es.jpg)
Got a weld in filler neck and cap from Cycle Haven with breathable cap thats was sitting pretty in the cupboard for a while so worked it into use.
(http://i64.tinypic.com/acpvz7.jpg)
(http://i65.tinypic.com/16ou1t.jpg)
(http://i64.tinypic.com/349auzm.jpg)
Seat base and handlebars next, unless the mudguards turns up soon then it'll be 'guard, seat, handlebars and sissy bar.
Ticking stuff off the list, slowly but surely.
(http://www.motohouston.com/forums/images/smilies/headbang.gif)
Totally cool retro-look gas tank.
This is so cool!!! Keep up the awesome work :cheers:
I don't have much input other than I've been enjoying following your work and I'm excited to see how this project turns out. Great job so far man!
OK Umbrella bike seems a bit off now that the tank is a bow, or arch or dome ... take your pick ...
Bow bike - could be a good one if you're dog lover, or a bow hunter.
Cool.
Buddha.
Got the petcock fitted and pressure tested to a degree. Two pin hole air leaks thats been plugged and holding a nice bit of pressure after realising, like an idiot, the sound of air coming out is the breather in the cap. Plugged that and all is good. Mounting points still to be decided and sealed to stop it rusting on the inside.
Mudguard turned up, an actual metal one this time, that came from a bike of some description, but its, well was, huge. 220mm internal width that needed to be reduced to 150mm to have any chance of fitting the 130 tyre thats nearer 140. Bonus is the mounting holes to the back that will be utilised again with some yet to be made brackets.
(http://i64.tinypic.com/30atnip.jpg)
(http://i66.tinypic.com/29eivm0.jpg)
And after meeting the angle grinder and welder.
(http://i63.tinypic.com/ffbmtk.jpg)
Still needs a bit of work as its not the shape of the wheel or I may leave it seeing as the rest of the bike is not exactly in keeping with the norm.
(http://i64.tinypic.com/mbsqk8.jpg)
(http://i68.tinypic.com/jzxu0k.jpg)
Once thats fitted properly I'll see what to do with the seat.
I was going to reshape the mudguard so I smashed it with a hammer and it looked exactly the same as it started so I just fitted it as it was. 12mm steel bar and more tedious lathe work to make the sleeves.
Without the use of a pipe bender small enough to take 12mm tubing I improvised with some bits of tubing and a vice. The mudguard had some handy pre taped M8 bolt holes and not one to miss an opportunity they where quickly used.
(http://i67.tinypic.com/2z7jyar.jpg)
(http://i65.tinypic.com/34odhs7.jpg)
(http://i67.tinypic.com/jk9bo8.jpg)
(http://i65.tinypic.com/mjppg3.jpg)
With the same bar I made the sissy bar which will later take the number plate, brake light and indicators.
Stuck the bar in the vice and pulled like a mofo until I got the desired shape.
(http://i65.tinypic.com/2zjhnqa.jpg)
(http://i66.tinypic.com/21ozblz.jpg)
Now I can finally work out the seat position and make it then once fitted I can sort out the foot controls and associated linkages, brake line and wiring for the brake light.
Love it! O0
Finally got round to sorting the chain but my precise measuring was a bit out by two links and as usual when trying to find the chain splitter you cant, its disappeared only to reappear when you've taken alternative routes and sorted the issue anyway.
The offering two links removed with the grinder
(http://i67.tinypic.com/2zznqtz.jpg)
And the chain as good as fitted
(http://i67.tinypic.com/11cgp4x.jpg)
Then I sort of started the seat, well, I say started, more like looked at it and thought about it and looked some more until I decided to make a chain tensioner instead. I bought a rubber thing off of eBay made for crossers and time will tell if its up to the task or if I'll end up using something else.
I tried utilising the original arm support and spring set up that came with the rubber thing but without making something completely overly complicated it wouldn't work. So I offered it up to near enough the position needed.
(http://i66.tinypic.com/4py49u.jpg)
Used some 3.5mm box steel left over from about four years ago... never throw any steel away... you'll always use it eventually...
(http://i65.tinypic.com/jfc8d1.jpg)
Cut the steel to size, got the flap disc on it to get rid of the surface rust, marked it out, drilled some holes, holes turned to slots to take an M8 bolt, rounded the plate where it meets the tube frame and rounded the tops.
(http://i63.tinypic.com/ip4b5v.jpg)
Sleeved the rubber thing with some more of the M8 sleeve I made from 12mm bar on the lathe a while ago, few washers and bolts ready to be cut to length, welder out and buzzed it on in a different place to start with but it works better here than there.
(http://i68.tinypic.com/al3hj9.jpg)
"What about the seat!" I hear you cry in much disgust... and my amusement... Its coming along, I have actually started it but you'll have to wait for the pics.
Is the chain simply sliding over the rubber bit there? That would worry me since it would wear away rather quickly, I think. Then the chain would be grinding on those bolts.
Its made from the same stuff as frame and swing arm chain guards and its a 3/4" thick so I'll have plenty of time to see if it works or not. I have two back up plans if this doesn't work involving a slimmed down skateboard wheel or a 520 front sprocket, but the sprocket will need machining and a bearing pressed into it
Trying to work out how to mount this seat is a bit like being pissed and screwing the crazy bird everyone avoids. It looks and feels good at the time but you come to regret it very quickly when the consequences of your actions bites you in the ass...
So I've got some three inch chrome springs to mount the seat on to take up some of the road blemishes and huge caverns the council call pot holes, nice and easy, just need to make a mount with a spring clip and jobs a good 'un. The hinge on the other hand needed a bit of titivating to make it not wobble and twist but still let the seat pivot in the up and down motion, which is always handy, being a seat n all.
So I started off with some 130mm sections of 12mm bar thats now being used pretty much everywhere on this bike, stuck it in the lathe and reamed the end down to 25x8mm
(http://i63.tinypic.com/ok68zn.jpg)
Threaded the end to M8 x 1.25, would of been a lot easier if I had some decent cutting dies, something else to add to the shopping list.
(http://i64.tinypic.com/2ibzwnr.jpg)
And utilised some M8 tie rod ends.
(http://i67.tinypic.com/2vxkqyb.jpg)
Another piece of sleeve and just like that, one weldable hinge where you can tighten the bolt and the seat will still move as freely as an illegal crossing the UK border.
(http://i63.tinypic.com/29bdb0w.jpg)
So what about the seat I hear you cry..... or maybe not then....
300mm lengths of yet more 12mm bar bent to shape.
(http://i68.tinypic.com/zy60c0.jpg)
And as far as I got this evening, bar roughly in place, ends need shaping to fit together nicely for welding and some more cross bracing needed for the rest of it. I may not even bother covering the seat but create a web effect with the bar and weld it all up. We'll see what happens.
(http://i67.tinypic.com/nwmov7.jpg)
So much rising anticipation and disappointment when I reach the last pic of updates! Definitely my favorite thread anywhere right now! ! Appreciate you posting!
Snow called work off for the end of the week... never mind, more time for seat building
I got so carried away I didn't take any pics of the in progress build so you'll have to make do with the sort of finished then mounted pics. It changed shape a bit as it went along but it seems to work pretty well.
(http://i64.tinypic.com/atluev.jpg)
(http://i65.tinypic.com/11vqm2t.jpg)
For the shape and angle it sits on the bike its pretty comfy as it is but thats mainly due to my fat arse.
(http://i63.tinypic.com/30sk2ep.jpg)
(http://i67.tinypic.com/29bcynl.jpg)
Now thats sorted within reason, It'll be foot peg position and associated brackets and foot controls.
(http://i65.tinypic.com/wwaqvp.jpg)
the seat is sitting a bit higher than originally planned but suits me alright. May drop it down on smaller springs, I'll see what its like when its on the road.
bad azzzz
Well, had a look at the seat, didn't like it so slept on it. Had a look again this morning, still didn't like it so it went. I shall be chopping and rebuilding a little 125 commuter after this so its been put aside for that, not to be wasteful and all that.
So, the seat decision was again in disarray, as was and is much of the build, so I do like most people do... bend some tube... well probably not most people, just me
(http://i64.tinypic.com/jrtrw7.jpg)
Getting the hang of the ring roller at last
(http://i67.tinypic.com/2n7qmf6.jpg)
Then worked out what I was going to do with the tube after staring at it for a bit longer than was probably helpful. Chopped out the curved tube, noted and profiled the rolled tube to make the seat frame
(http://i67.tinypic.com/iwrsdk.jpg)
Used a bit more to make the back arch and something to stop me sliding off the back of the seat pad
(http://i67.tinypic.com/2hpooyg.jpg)
Welded it on
(http://i67.tinypic.com/2mr5ncy.jpg)
Just the actual seat pan to make for the foam to stick to and be covered in most likely leather.
Then made some tank mounts
(http://i66.tinypic.com/mb4wo3.jpg)
(http://i64.tinypic.com/fp2ctu.jpg)
I seem to have an attachment to 12mm bar now, seeing as its used everywhere. Perhaps I should name the bike 12mm, that'll confuse some people.
Trial fit for my ample arse, wedges in there fine
(http://i65.tinypic.com/2iqhb1v.jpg)
More things ticked off the list that I keep adding more things to... I can see this being one of those never ending project bike builds...
So wickedly cool! Hardly even recognizable as a GS after all the work you've put into it.
Thanks for sharing with us all!
+1 !!!
I am loving this thread :cheers:
This looks motherfuckin badass dude!
But after you've made the new "seat", you are now sitting literally on the frame, don't you? Won't that be a little "stiff"?
Like you would get every vibrations from the street directly transferred to your spine?
I'm making a seat pan to sit where I'm sat, then using a 2" thick piece of upholstery foam shaped to suit and covering it with leather. I make most of my hardtails with a solid mount seat, the position you sit makes all the difference to comfort or pain.
Couple of little bits sorted, in-between the snow, dodging d**kheads who cant drive for sh*t and trying not to freeze my balls off.
Stripped the rear brake off the old frame and fitted it in place, the old torque arm wasn't long enough so I chopped the ends off and used the same 20mm square tubing to create a new one but with a bit of a bend, thanks to a four foot piece of tubing.
(http://i66.tinypic.com/a1ih6g.jpg)
(http://i64.tinypic.com/2vsnjbk.jpg)
Made a bracket and welded that to the frame and now the rear brake is sorted apart from a hose once the foot pegs are fitted in place
(http://i66.tinypic.com/1znmv07.jpg)
For the foot pegs and levers I was going to make some from scratch but seeing as there was nothing wrong with the originals, the pegs are on their own bootable backing plate and everything worked it should before disassembling for chopping I'm going to use them instead.
I cut the mounts from 12mm plate and pre drilled it ready to be tapped to M8, same as originally used. The only bit I need to make or modify is the gear pedal as it was mounted directly to gearbox shaft, meaning I need a link arm and a couple of threaded rose joints.
(http://i63.tinypic.com/2hqqdmu.jpg)
Once thats sorted its mainly gussets, electrics box, battery tray or box, sort out where the wiring will run and hide as much as possible, decide on indicators, switch gear.......
sweee-eeet :bstar: :bstar: :bstar:
This is one of my favorite threads going. Great job. :cheers:
As Judas Priest sing: Breaking the Law breaking the LAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAWWW!!!!!!!
Well, wrong sort of braking but near enough. They are sort of important though for the idiots who don't look where they are pointing the steel killing machine. Unless your Steve McQueen, then you don't need brakes. F*cking legend.
So, brakes it was along with foot pegs and associated bracketry and linkages. First order was the mounts. Had some new taps arrive, just as well as I snapped the last M8 on another job. With that sorted the holes in the foot mounts where taped, some tubing notched and cut to length. I'll make some flanges to weld in to hold it all nicely later on.
(http://i68.tinypic.com/mr8fgn.jpg)
Bolted the foot peg plates to them and tacked it in place at 34.6 degrees. Not for any particular reason but thats what the angle finder said it was, and now you dont need to wonder no more. Your welcome.
(http://i67.tinypic.com/oa96d1.jpg)
I chopped the master cylinder mount from the foot mount as it wouldn't work where it was, hitting the engine casing, so I'll mount that on the frame later.
(http://i68.tinypic.com/17s30g.jpg)
So, now its a bit later... master cylinder getting positioned for mounting
(http://i68.tinypic.com/2dw4un5.jpg)
The foot brake lever wasn't the right angle to reach easily for use so I cut and widened the gap, bending the peg closer to my foot and ease of reach.
(http://i66.tinypic.com/971a28.jpg)
Got the master cylinder mounted then the associated linkages. Roughly a 2-1 lever action from the rod to the cylinder giving a small amount foot travel to a twice of cylinder travel making for a nice easy braking feel. Used some M10 threaded bar, turned down to M8 and threaded to take the tie rod ends.
(http://i64.tinypic.com/a4n12d.jpg)
Then after various attempts at the gear linkage I got it working spot on. Some more M10 threaded bar turned down to M8 and threaded for the tie rod ends. I'll probably switch out the threaded bar for some normal 12mm bar later on.
(http://i64.tinypic.com/24d4t4o.jpg)
Tomorrow it may be exhausts or it may be side stand and coil mounts and what ever else I can think of.
Wow, you're showing me that pretty much anything is possible with a bike build!
Well anything with a skilled pair of hands and a good eye at least...
Love how you've totally reversed the fore and aft of the pedal assemblies.
I love this thread. Your work makes my feeble attempts at modification look, well, feeble!
Please keep posting!
Well the exhausts won the toss of what to do today, apart from they needed making I also kept on falling over the headers. I had various designs for the exhausts batting round my head, most of which where pretty ridiculous, but ended up going with the initial idea of under the engine.
Utilising the original end can
(http://i65.tinypic.com/726q92.jpg)
Chopped the end off... these stock exhausts are so restrictive
(http://i66.tinypic.com/2e514c8.jpg)
Marked out for the new length
(http://i68.tinypic.com/2dnrq1.jpg)
And ended up with this after smashing what was left of the baffles out
(http://i64.tinypic.com/13yf1ib.jpg)
End cap positioned, new length loud stubby empty can
(http://i65.tinypic.com/64njty.jpg)
End welded on
(http://i68.tinypic.com/9hp98p.jpg)
Had to lengthen the headers and change the angle of the exhausts so they met in the right place
(http://i67.tinypic.com/35j055x.jpg)
(http://i68.tinypic.com/24mf0yf.jpg)
End can ready for mating to the headers
(http://i63.tinypic.com/2dafxg0.jpg)
(in the voice of David Attenborough) Mating successful, there should be a new breed of end cans arriving in about 9 months
(http://i63.tinypic.com/dwuzpl.jpg)
And as it sits on the bike now. I'll make a proper spacer for the hanger rather than a couple of bolts
(http://i65.tinypic.com/muv24o.jpg)
(http://i67.tinypic.com/34gnhhj.jpg)
Just shy of 2" of road clearance so should be ok, only sparks will tell
Good stuff man. That exhaust looks like it will be loud as all hell lol.
Will be real interested in how your clearance turns out,...... My header is around the same " as yours and I've scraped a couple times already.
(https://www.motohouston.com/forums/images/smilies/mblah05.gif)
After having way to much fun on my VS1400, I thought it was time to do a bit more on the GS project. Had a bit of a dodgy back as well so Ive altered the seating position a bit to ease the sciatica.
I bent a couple of rails up to lift the seat height to a more comfortable and manageable height and in doing so its giving me somewhere to make an electrics box incorporated into the seat.
(http://i63.tinypic.com/2rqoh1v.jpg)
Then it was time to make yet another random bodged up tool for bending tubing for the exhausts to replace the piece of god awful crap I made before. Grabbed a bargain die from eBay, made a former and slung together the rest from bits lying around the garage.
(http://i67.tinypic.com/2zi4mdf.jpg)
(http://i67.tinypic.com/qod1er.jpg)
And it even worked like it was meant to!!
(http://i68.tinypic.com/sfgcwo.jpg)
Bent with an offset for the side exit... note the right exhausts about 2" shorter than the left... thats what happens when you get cocky with the new toy...
(http://i65.tinypic.com/24lk60x.jpg)
And rectified with a 2" section welded in. All thats needed is a slight adjustment on the angle to get it to follow the bottom rail a bit better. Apart from that it worked pretty well and was almost a one piece bent exhaust.
(http://i65.tinypic.com/50nol2.jpg)
(http://i66.tinypic.com/2ytzho1.jpg)
So electrics box next, then seat pan and what ever else it needs
I think this looks and works much better bossman!
Doggin' on, as you do.....
Plenty of things crossed off the list today. Exhausts have been bent a small bit to bring them inline with the frame rails
(http://i67.tinypic.com/21mauz8.jpg)
Welded a plate under the tank to mount the coils and help with the throttle / clutch cable routing
(http://i65.tinypic.com/rsbdd0.jpg)
Utilising the last bit of 12mm bar I had bored out before, it was drilled through the frame rail to make part of the manifold support utilising some threaded bar and nuts, one drilled out and one stock to secure the bolt.
(http://i63.tinypic.com/vgmlwx.jpg)
I had a brake light and number plate holder hanging around for a while so I used that welded onto the sissy bar
(http://i68.tinypic.com/1z4zhn5.jpg)
Then it was seat fabrication. Any excuse to get the plasma cutter out.... but don't cut over plastic saw horses.... they melt in a fraction of a second. Bit of 2mm sheet steel
(http://i66.tinypic.com/11givth.jpg)
Profiled to the frame rails
(http://i64.tinypic.com/10h0tiq.jpg)
Configuring the back panel
(http://i67.tinypic.com/px6o7.jpg)
(http://i63.tinypic.com/20hr7kn.jpg)
(http://i63.tinypic.com/fmmoli.jpg)
(http://i68.tinypic.com/2d6pocw.jpg)
Welded in a bit of bar around the radius to strengthen the upstand
(http://i64.tinypic.com/2hh12js.jpg)
And cut some upholsterers foam ready for a leather seat cover that I've yet to decide on... but its going to be black.... no hipster shaZam! yourself colour seat here
(http://i63.tinypic.com/jfeyvo.jpg)
Sorted out some cable for the clutch and brass nipples to suit from a kit I bought a couple of years ago. All in all this kit has done three bikes with both clutch and throttle cables.
(http://i66.tinypic.com/sd3d02.jpg)
Throttle cable with the smallest nipple possible to suit the VM carb.
(http://i66.tinypic.com/2a5fwpw.jpg)
VM's have got an internal spring so only need one throttle cable, no need for return cable
(http://i67.tinypic.com/2cxi6hd.jpg)
From past experience working with VM's, its easier to clamp the cable with the spring tight to get the cable located in the slide
(http://i64.tinypic.com/214djo.jpg)
(http://i64.tinypic.com/211ukg6.jpg)
Cable fed through the cable guide
(http://i68.tinypic.com/260pi78.jpg)
Spring in place
(http://i66.tinypic.com/2f0f4ok.jpg)
And fully assembled ready to go
(http://i64.tinypic.com/nqe83s.jpg)
Might even get the bike sorted for paint before christmas at this rate but I wouldn't hold your breath
great tip on clamping that cable! ive fought with those mofos before! :thumb:
Great update and thrilled to see your progress!!
I'm interested to see how the engine run's with the single VM carby. Have you done any testing?
I want to run twin Keihen FCR's on my bike, but iv'e never seen it done and it's and expensive venture.
Your doing a mad job on this build old mate, totally full on.
Have I done any testing :laugh: :laugh: :laugh: :laugh: Of course not. Its a hit or miss situation but I'll be able to put the twin carbs back on if need be but hopefully I wont have to. I may loose a bit of power top end but its not going to be a speed machine especially with a solid mounted seat on a hardtail.
LOL. GS's ain't no speed machine. But ya still want to launch of the line right?
Continue on sir.