Hi so first thing i better so is introduce my self, my name's Rob, and I thought I would post up my new project, having changed jobs recently where i can viably ride to work, i thought it would be a good excuse for a new bike build.
I want this to be a much faster build than my last one (cb200) http://www.dotheton.com/forum/index.php?topic=43873.6 as I want to be riding it to work in the late spring! we'll see how this pans out.
Im basing this build on a GS500 because they are cheap and plentiful, so parts are easy to come by and I can do a decent enough resto of the rest of the bike as i go without breaking the bank!
I've been posting this elsewhere but figured this would be a better place for it, so I'm going to quickly bring this thread up to speed.
This is the inspiration:
(http://i1036.photobucket.com/albums/a441/Rob_Whittle/IMG-20160820-WA0004_zpsifrnahyu.jpg) (http://s1036.photobucket.com/user/Rob_Whittle/media/IMG-20160820-WA0004_zpsifrnahyu.jpg.html)
(http://i1036.photobucket.com/albums/a441/Rob_Whittle/IMG-20160820-WA0005_zpssdukpo0y.jpg) (http://s1036.photobucket.com/user/Rob_Whittle/media/IMG-20160820-WA0005_zpssdukpo0y.jpg.html)
I have no idea who built this, but i love the simplicity of the new sub-frame and it has inspired me to build something similar.
And so it begins...
(http://i1036.photobucket.com/albums/a441/Rob_Whittle/IMG_20170120_202131_zpsp0uhsxpj.jpg) (http://s1036.photobucket.com/user/Rob_Whittle/media/IMG_20170120_202131_zpsp0uhsxpj.jpg.html)
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So ive started with a project bike and a spare frame, first thing that ive done is cut the nasty rear sub frame of the back of the bike, it really is a nasty bit of box section! Ive then welded some plates to fix up the frame and am currently waiting on some plasma cut brackets to weld on to it. Its looking better already!
(http://i1036.photobucket.com/albums/a441/Rob_Whittle/IMG_20170128_211833_zpsupakcyys.jpg) (http://s1036.photobucket.com/user/Rob_Whittle/media/IMG_20170128_211833_zpsupakcyys.jpg.html)
(http://i1036.photobucket.com/albums/a441/Rob_Whittle/IMG_20170128_211841_zpsmnqzvenc.jpg) (http://s1036.photobucket.com/user/Rob_Whittle/media/IMG_20170128_211841_zpsmnqzvenc.jpg.html)
8mm steel plate Brackets:
(http://i1036.photobucket.com/albums/a441/Rob_Whittle/seat%20frame%20bracket_zpspfw4edls.jpg) (http://s1036.photobucket.com/user/Rob_Whittle/media/seat%20frame%20bracket_zpspfw4edls.jpg.html)
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Welcome to the site Rob! Awesome thread, I'll be following along for sure :cheers:
knowing the limitations of my metal bending capabilities I found a friendly fabricator who made this seat frame up for me on eBay to my dimensions. You can see it below on the parts bike to give an idea of scale, its more rounded than the frame on the inspiration bike but i wanted it to be a softer look and a narrower seat to make the Tyre look wider. :D
(http://i1036.photobucket.com/albums/a441/Rob_Whittle/IMG_20170128_211908_zpsrqwegarx.jpg) (http://s1036.photobucket.com/user/Rob_Whittle/media/IMG_20170128_211908_zpsrqwegarx.jpg.html)
(http://i1036.photobucket.com/albums/a441/Rob_Whittle/Motorcycle%20seat%20tube%20REVC%20Low%20Res_zpsbm50rown.jpg) (http://s1036.photobucket.com/user/Rob_Whittle/media/Motorcycle%20seat%20tube%20REVC%20Low%20Res_zpsbm50rown.jpg.html)
(http://i1036.photobucket.com/albums/a441/Rob_Whittle/IMG_20170128_212038_zpsu0ea9jmf.jpg) (http://s1036.photobucket.com/user/Rob_Whittle/media/IMG_20170128_212038_zpsu0ea9jmf.jpg.html)
(http://i1036.photobucket.com/albums/a441/Rob_Whittle/frame_zps6fa6cu3o.jpg) (http://s1036.photobucket.com/user/Rob_Whittle/media/frame_zps6fa6cu3o.jpg.html)
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Ive also machined up some brackets on lathe for the new bolt on subframe. I made these at HACKSPACE london, if any of you guys are UK / London based you seriously need to check out Hackspace, I cant praise it enough.
(http://i1036.photobucket.com/albums/a441/Rob_Whittle/mount%20lugs_zpsrnr6qrvd.jpg) (http://s1036.photobucket.com/user/Rob_Whittle/media/mount%20lugs_zpsrnr6qrvd.jpg.html)
(http://i1036.photobucket.com/albums/a441/Rob_Whittle/MmsCamera_2017-02-04-14-25-44_zpsyzjanzou.jpg) (http://s1036.photobucket.com/user/Rob_Whittle/media/MmsCamera_2017-02-04-14-25-44_zpsyzjanzou.jpg.html)
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I've also rebuilt the carbs with a 147.5 main jet, new seals etc - I'll be putting on a Delkevic full exhaust system and pod filters so hopefully it won't be running too rich!
(https://uploads.tapatalk-cdn.com/20170208/b6f8639b6b3e687ba7da73d4f825b356.jpg)
(https://uploads.tapatalk-cdn.com/20170208/fa2cc28cdca129655cb16af74eacb987.jpg)
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So I've welded up and ground down the lower subframe arms this evening, due to the angles involves they couldn't be bent in the garage so I've made them out of schedule 10 stainless bends and pipe - my first time working with stainless and probably my last 😂
(https://uploads.tapatalk-cdn.com/20170208/a104e545b30f812594c46de4082557c5.jpg)
(https://uploads.tapatalk-cdn.com/20170208/108200383aa0b01ad11f9c27d4d651ae.jpg)
I did buy this little badboy the though, worth its weight in gold! And did a great job of finishing up the welds.
(https://uploads.tapatalk-cdn.com/20170208/07052758032313f5455cca3d677f2456.jpg)
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This arrived in the post today too - A katana (gsx750) rear wheel for a wider rear tyre!
(https://uploads.tapatalk-cdn.com/20170209/cad8042d549c41979bdbbc691ae10207.jpg)
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Brackets have turned up, I just need to get them tacked up and get the subframe notched and mounted up.
(https://uploads.tapatalk-cdn.com/20170225/1cee72532f5764b1a8c363874d305c22.jpg)
(https://uploads.tapatalk-cdn.com/20170225/612fb971fa852f4af10bf3a9770fac8d.jpg)(https://uploads.tapatalk-cdn.com/20170225/2b4a546d50b1f78feceb69ba2e731b47.jpg)(https://uploads.tapatalk-cdn.com/20170225/b6b06f1b10810c30c98c2bdecc19be35.jpg)
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So I've started notching the subframe tubes I went the traditional route and semi eye balled it with a notching template that you can find online.
(https://uploads.tapatalk-cdn.com/20170226/5b20712b6f345d2d221533fe670089c7.jpg)
I also used a jubilee clip to get some straight lines around the circumference of the tubes. (https://uploads.tapatalk-cdn.com/20170226/bab63fae6bdac98503ab0c8d475eb166.jpg)(https://uploads.tapatalk-cdn.com/20170226/cf0c1e70a561bb8d345eff9c291919f6.jpg)
Fitted the template inside the jubilee then traced over it to give the waste that needs to be removed
(https://uploads.tapatalk-cdn.com/20170226/ac39fe5676bd3c487c5023c78ccb49b8.jpg)
Removed the waste tube with a hacksaw slowly, then tidied it up with the mini belt sanded that just so happens to have a 1" diameter top roller so it made tidying up the notching a piece of cake!
(https://uploads.tapatalk-cdn.com/20170226/7e79bdbb891cbfc4538bd62a9934bf4b.jpg)(https://uploads.tapatalk-cdn.com/20170226/5f6b00b576ed0e92355ada5cb7f95c33.jpg)
(https://uploads.tapatalk-cdn.com/20170226/41f19570a4eaed93ed133526656c0c70.jpg)(https://uploads.tapatalk-cdn.com/20170226/d004c47283ee656cc6135fded33d3590.jpg)
[emoji108]
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Things are starting to move forward now! This afternoon I've tacked on the upper brackets and tacked the upper subframe, once I'm content I'll take it down to the local fab shop and get it tigged up.
(https://uploads.tapatalk-cdn.com/20170226/a5ec23ef347a25cb35004775e694886e.jpg)
(https://uploads.tapatalk-cdn.com/20170226/73e354d09cdbd56cc1d10841ff9b2278.jpg)
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I jigged up the lower mounts last night (https://uploads.tapatalk-cdn.com/20170301/0c04fe5a3e66921c814c304483f22b93.jpg)
(https://uploads.tapatalk-cdn.com/20170301/e55ac2220c4dd5c7f90f3f198ae5f7a8.jpg)
And notched the lower stainless legs, which was really very easy - not sure what I was worried about now!
(https://uploads.tapatalk-cdn.com/20170301/082b0a7b1d0ed5fe253a8c875f1bd8ff.jpg)
(https://uploads.tapatalk-cdn.com/20170301/7af6b62d36cd7518306a1b57e9c3b1bd.jpg)
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So I've got the lower legs tacked on today, and it's starting to take shape!
(https://uploads.tapatalk-cdn.com/20170301/61c998500c06613d3dca2aa3c378eea9.jpg)
(https://uploads.tapatalk-cdn.com/20170301/3514dec9bd2ef1377fbc5f2b67cd56df.jpg)
(https://uploads.tapatalk-cdn.com/20170301/6caf1edfd401846ef705699637927d2f.jpg)
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So my frame is off at the fab shop being welded up, so whilst I wait for the frame to come back and a stream of parts to arrive I have been playing around in Photoshop, I'm thinking of a very simple colour scheme like this, what do you guys think?
(https://uploads.tapatalk-cdn.com/20170308/5f92ab870170563bef1e75b10e715744.jpg)
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So I picked up my frame early this morning from the fab shop, really glad I paid to have this welded professionally, so much better than I could have done in the shed!
(https://uploads.tapatalk-cdn.com/20170307/22724b3b7d04c8de2882ca9d112a1b71.jpg)
(https://uploads.tapatalk-cdn.com/20170307/97b5a009b5dd6e8ef36f15fc50c470a6.jpg)
(https://uploads.tapatalk-cdn.com/20170307/cc053ac4410ef742b1110071734e95f3.jpg)
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Modified frame as it currently stands after a bit of tidying up of the welds, Its off to be shot blasted tomorrow! (https://uploads.tapatalk-cdn.com/20170308/abf9abd3bf93cca267166a95b8d37f0b.jpg)
I also had some near new front shocks delivered today so will start rebuilding the front end shortly. More to follow soon!
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Today I got my new forks fitted and my clipons arrived in the post so i got them fitted on too, it's starting to come together i just need a front brake lever and a fresh headlight and the front ends pretty much done
(https://uploads.tapatalk-cdn.com/20170313/7fe79517f43a2b6d2e679f16c9d87597.jpg)
(https://uploads.tapatalk-cdn.com/20170313/c605ab1c60b2e82c92675cc62186337e.jpg)
(https://uploads.tapatalk-cdn.com/20170313/3802171a3436bd1a46a760ca81d146c5.jpg)
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So this evening I made a start on stripping back on of my fuel tanks ready for a coat of epoxy primer.
The paint stripper here in the UK is shocking, due the EU regulations they took the good stuff out of it, so it would barely touch emulsion paint let along 2k clear. After adding some of the good stuff back into a can of normal paint stripper it went through the paint on the tank like a knife through butter. I DO NOT recommend doing this, and it was carried out in very well ventilated area with all the PPE I could find.(https://uploads.tapatalk-cdn.com/20170317/f08bcefae9f083a653d025a92ced2f56.jpg)(https://uploads.tapatalk-cdn.com/20170317/a49e6bd1e7e924a15ee57fc1fdf6c8ab.jpg)
This is the finished result after hitting it with a wire brush on a grinder, next job is to kill the rust with some jenolite and hit it with some Epoxy primer.(https://uploads.tapatalk-cdn.com/20170317/f7bda48fe6b5b3edf2b634a94958e34e.jpg)(https://uploads.tapatalk-cdn.com/20170317/40466594bfd2bfb323e2ab9b8293fcde.jpg)
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Tank filled and in primer(https://uploads.tapatalk-cdn.com/20170319/ce57f1ba12329e3fa7e773f15f30a019.jpg)
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So that's where I have got to so far! Apologies for the rapid fire posting, hopefully it makes sense, more to follow soon!
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Rapid fire postings are the best when in a project thread :thumb:
Love the work so far!!! Always enjoy seeing a GS get some TLC :kiss3:
Looks great so far man. Keep it up!!
Welcome and looking forward to the build! :woohoo:
Great looking build Moto!
Looks a bit like my own bike :D
I also created a thread about stripping the tank down to bare polished metal, then clear powder coated it.
Keep us updated!
Cool build! Fun to see good ole fashioned garage engineering. Is that evolution powertool thing a mini belt sander?
Thanks guys, I'm really enjoying this build so far! Everything is just easy.
If your in the UK screwfix sell them. Really really useful bit of kit, one of those things where I'm not sure what i did without it now!
http://www.screwfix.com/p/evolution-minibelt2-thin-belt-sander-230v/54960 (http://www.screwfix.com/p/evolution-minibelt2-thin-belt-sander-230v/54960)
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This is one of the most thoughtful mod pages I have seen.
I like the design work. The raised rear end may be a problem with seat angle, depending on how you shape it. You may end up balls on tank and a lot more arm load than you need.
I really like the inspiration bike. Very clean and sparse without being kiddie bike looking. Perhaps the under seat pan could have been better designed . Perhaps to include a stop/brake/plate light and a faired in plate.
I really wait to see where you go with this. My project has be stagnant for months as it has been too hot in the shed ( up to 45deg C) to work in there. Just cooling down now but so many jobs have accumulated, it may take time to get back to the poor GS.
Awesome work, man. Nothing quite like the feeling of designing and machining your own parts for any project! Not too many "maker spaces" like that where I live, but I'm spoiled by my dad's old Bridgeport. Loving the clip-ons too... may end up with a pair of those myself! Nice and tidy.
Moto - you got mad skills.
But is there a reason you opted for round tubing ? easier to bend with tubing bender - yea, but the square tubing to round tubing swap seems to give me a bit of "catch my eye" feeling.
Its pretty cool anyway.
Cool.
Buddha.
Thanks Buddha, I went for round tube because I like the contrast with the boxy frame, it's also alot easier to fabricate and doesn't fold up on you like box section tends too.
I'm looking to do a cognitomoto style rear brake light on the subframe, just need to grow a pair and get on with cutting a slot for an led light like the below, it deals with the brakes and indicators in one hit.
(https://uploads.tapatalk-cdn.com/20170322/c41a3be37ce53a2daa22ee53fc7c9423.jpg)
(https://uploads.tapatalk-cdn.com/20170322/87a4dba51e878e01b232acd471635caf.jpg)
(https://uploads.tapatalk-cdn.com/20170322/bcc0c895d2a353fc3e58c645c1a9ff90.jpg)
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Next thing i need to source is a small lithium battery, I've been looking at a tiny anti-gravity battery, i think endo potential used one on his build, any one have any experience with them? Are they man enough for day to day riding?
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(https://uploads.tapatalk-cdn.com/20170322/a8bb34e073039e334087935e21c0f032.jpg)
I use Shorai's. Had good service from an SSB as well ( after the first one was replaced at new with a dead cell). Don't know if they are available everywhere. You don't need a tiny one. The LIPoly and LIFePO4 batteries are smaller and lighter ( a lot) than lead acid batteries for the same capacity, and having no fluid they don't care about orientation, so it is east to find a spot for them.
So far so good on my Antigravity battery (I think it even helps levitate my rear end, haha)
I only ride the bike every couple weeks, and it's always started without a hitch for the past 9 months.
The reason for wanting to use the smallest battery possible is because I want to keep the rear end as visually thin and light as i can. With the anti-gravity 4 cell it should fit within the new rear sub frame like the image below.. fingers crossed.
(https://uploads.tapatalk-cdn.com/20170323/1e10b6320cc6179d250509b0e8c047ff.jpg)
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You might need a higher capacity battery or several in parallel ( that would still fit) to get reliable starting. That's only 6AHrs. 2 would probably do.
If you are were going to make one of those "cafe" racer type rear seat humps a blockier one would fit in that easy and stealthily. You could make a deeper spot under the front of the seat and keep the thin look. The taper from say 80mm deep, back to flush would actually make the rear LOOK thinner, especially if you curve it ( externally concave). Also the advantage of saving having to rewire with heavy gauge wire over a longer run.
I checked my battery, and turns out I have the Antigravity 8, not the 4...
Quote from: moto on March 22, 2017, 03:55:46 AM
Thanks Buddha, I went for round tube because I like the contrast with the boxy frame, it's also alot easier to fabricate and doesn't fold up on you like box section tends too.
Someone told me he fills up the tubing with sand and plugs the ends (I guess with a welded up plate) and square tubing can be bend over a roller - like a car wheel, or a caster for a assembly line etc - with a long pipe over it - no mandrel required cos - well its flat. And it doesn't collapse etc etc. No idea, I've not seen him do that.
Cool.
Buddha.
Would I need more than 6ah ? The 8 cell is only 8ah, maybe I'll start with a 4cell and see what happens!
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STD battery is 11AHr but what really matters is the cranking amps.
I don't know much about the charging system on a GS500 but I would think that the alternator outputs enough to run lights etc and charge the battery? If so you comment about cranking amps would be spot on. I'll give it a go.
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So i went on a tour around the Morgan Car factory on Friday and it got me thinking about colour schemes. I've been playing with Photoshop this morning. What do you guys think?
1)(https://uploads.tapatalk-cdn.com/20170326/684f9470f19cb1055acc11736c821f5e.jpg)
2)(https://uploads.tapatalk-cdn.com/20170326/c571aab27ca3f2276d093cecdad2dff8.jpg)
3)(https://uploads.tapatalk-cdn.com/20170326/592c6339759c9443c7d0dca1002e377d.jpg)
4)(https://uploads.tapatalk-cdn.com/20170326/1aa49bf0e838dfecbd4b9ab324ce5423.jpg)
5)(https://uploads.tapatalk-cdn.com/20170326/ad13827e0c4802a1b0a3752560e3f0b2.jpg)
6)(https://uploads.tapatalk-cdn.com/20170326/e2f8334048ef9bd6e6a5215ff55ad025.jpg)
7)(https://uploads.tapatalk-cdn.com/20170326/43a3efa01d42d8775c8a41f93a17e6a6.jpg)
8 )(https://uploads.tapatalk-cdn.com/20170326/6dd61710f4b388cb569a33bc50481bed.jpg)
9) and just because...
(https://uploads.tapatalk-cdn.com/20170326/0cb454fb63d3ef22f2a969312777d970.jpg)
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Orange wheels, grey tank, black seat :thumb:
i'll second that qcbaker :thumb: :cheers: i think the black subframe makes all the difference, it's all about the subtleties.
thouroghly enjoyed looking through the thread moto, your metal work is sublime :thumb: looking forward to seeing more.
Thanks, I'm having great fun building this one!
I've done another a few more, I'm starting to agree with the black subframe!
10 (https://uploads.tapatalk-cdn.com/20170327/4ac169f48fff78d548edf16408c18749.jpg)
11 - not so subtle..(https://uploads.tapatalk-cdn.com/20170327/7c5cc9af87d8a8a25070b573ebcf7bf3.jpg)
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That last one is pretty close to what I'll be running, minus the rear-end chop. I've got an orange tank and plan on running it with the some of the black on the original bike.
That custom tail and brake light looks pretty slick. :thumb:
Orange and white looks like a KTM...
I like the burgundy seat and white sub frame. White or burgundy (metallic) wheels as well?
My vote will 99% of the time be for something bright, unique and flashy! (Yeah I know my bike is silver/black but I've got two other vehicles that are very eye-catching... so... it's nice to blend it a little once in a while ;) )
white is horrible to keep clean. polish the tank, have it clear powder coated, then do a color paint coat over it for decals, then clear coat it with paint again.
Polished, powder and paint, that sounds like a whole world of pain ! 😂 My last paint job was orange metal flake on a cream base, that was hard enough! This one i just want to hit with one colour basecoat and clear it!
(https://uploads.tapatalk-cdn.com/20170328/6a0d6b9da162e5e0e25e565ac60110f6.jpg)
(https://uploads.tapatalk-cdn.com/20170328/f8486d59794249337f351b6cd467687f.jpg)
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Beautiful!!! :rstar:
Quote from: qcbaker on March 26, 2017, 08:44:01 PM
Orange wheels, grey tank, black seat :thumb:
The Gulf color scheme looks good on just about anything on wheels, but the simpler color scheme above would also look great as well.
Maybe an orange stripe down the middle of the tank just to add a bit more color?
Welcome to ze nuthaus :)
Aaron
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Like this? Could drop in a metal flake strip on the tank, I do love a bit of 70s style hotrod metal flake ;D and i do have have left over paint and flake from the last build.... ::) so much for a quick and easy build!!
(https://uploads.tapatalk-cdn.com/20170328/b8d6022c6a57fab0ba1347f8512c3c20.jpg)
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My led rear light turned up today
(https://uploads.tapatalk-cdn.com/20170328/97627d288eb2b8aa8e27cfc5b77ecdf5.jpg)
I'm looking at frenching it into the rear subframe, the challenge is to do it right it needs a flat base to stick to. I've looked at rolling a bit of box section and welding it it, but it always folds up on me, so i am having three pieces lazer cut out of sheet steel and I'll tack them together then weld the whole piece into the rear subframe.
(https://uploads.tapatalk-cdn.com/20170328/515f79b273c69a2cc07e2bfc98321764.jpg)
(https://uploads.tapatalk-cdn.com/20170328/53db377fcdabdc2d3390308c2d74b65d.jpg)
(https://uploads.tapatalk-cdn.com/20170328/1d68bd9fd0879d3b68e3a63b793da376.jpg)
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Quote from: moto on March 26, 2017, 01:34:34 AM
So i went on a tour around the Morgan Car factory on Friday and it got me thinking about colour schemes. I've been playing with Photoshop this morning. What do you guys think?
9) and just because...
(https://uploads.tapatalk-cdn.com/20170326/0cb454fb63d3ef22f2a969312777d970.jpg)
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OOoo morgan factory ... you're making me cry.
Anyway I like that one above.
Cool.
Buddha.
The Morgan factory was the nuts. Watching the old boys make new cars with almost forgotten skills in mass production is really humbling.
(https://uploads.tapatalk-cdn.com/20170328/07a324d7c23befca2ac4c4da3b4b4f63.jpg)
(https://uploads.tapatalk-cdn.com/20170328/282f4f9bf4d3f439c4aca83861203150.jpg)
(https://uploads.tapatalk-cdn.com/20170328/5104ac6d905a23f6b34b4c0b7b33646d.jpg)
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My tyres also turned up today, part worns, loads of tread left, and 1/6th the price. 👍
Continental road Attacks
Front 110/70/17
Rear 160/60/17 (GSX750 rear wheel)
(https://uploads.tapatalk-cdn.com/20170328/dc58d13c657fe9230ea757554497470b.jpg)
(https://uploads.tapatalk-cdn.com/20170328/5bd9ad2fa5956bc199bfafc9a2f7c68f.jpg)
Just waiting on the frame and wheels back from the powder coater and we can get this puppy rolling!
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oops
Quote from: moto on March 28, 2017, 08:48:37 AM
Like this? Could drop in a metal flake strip on the tank, I do love a bit of 70s style hotrod metal flake ;D and i do have have left over paint and flake from the last build.... ::) so much for a quick and easy build!!
(https://uploads.tapatalk-cdn.com/20170328/b8d6022c6a57fab0ba1347f8512c3c20.jpg)
This with the orange wheels would look awesome!
Or did you already powder coat them black?
That LED tail hoop will be fantastic. I was tempted to get the CognitoMoto for my build, but couldn't justify the $310 they wanted.
I do love their bikes though.
(https://2.bp.blogspot.com/-HTyNwZJcIy0/VXIEge-5ABI/AAAAAAAAlBw/UjMkpOZtPv4/s640/honda-cb550-caferacer-10.jpg)
Yea the cognitomoto hoop is fantastic. But I agree it is way over priced for my build too, my base bike cost me half that! If I can even get halfway to their quality i will be over the moon!
The other thing is i have already made the subframe, cutting off the rear hoop now and welding on a new one would be very difficult to get right!
I had to make a choice on the wheel colour this afternoon, they are going to be satin black as it give the most flexibility with the rest of the colour scheme, and they can always be changed! The powder coat guy i use only charges £20 a rim.
Frame will be be a light Matt textured black, always like changing up blacks with different textures and gloss levels
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Gorgeous! There are a few SV650s with that colour schene (no cream, just the copper), and they are magnificent looking!
The first bits came back from the powder coater today, they did a great job on the wheels, new bearings and the tyres on and they'll be good to go!(https://uploads.tapatalk-cdn.com/20170403/ce28a90d34c4c43fa9a3a1c446ac9229.jpg)(https://uploads.tapatalk-cdn.com/20170403/e496c2cc00e2eb184beea091754e11ce.jpg)
(https://uploads.tapatalk-cdn.com/20170403/fa096f1871e38409e94f890c3c349a85.jpg)
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I got the tyres mounted and disks on this week which is a step forwards, they need a good clean though!
(https://uploads.tapatalk-cdn.com/20170409/eff08a5e7d04f6df36bce790e5e4320d.jpg)
I also got the base coat and clear on my tank. BMW pepper white, it needs a wet sand but is coming together!
(https://uploads.tapatalk-cdn.com/20170409/6a940b0735c6457223e279eb683f5af4.jpg)
(https://uploads.tapatalk-cdn.com/20170409/ec33eb04d3377ff3456cef636d7a13e5.jpg)
(https://uploads.tapatalk-cdn.com/20170409/db10c2b06c54543961d1937037034a52.jpg)
I'm really behind on my threads, but hot damn! This is one I will be watching! Great job! :cheers:
A new headlight arrived from China today, it had led indicators built into it so will help keep things streamlined!
(https://uploads.tapatalk-cdn.com/20170411/8220c5c25b81afb08160ff08db06742a.jpg)(https://uploads.tapatalk-cdn.com/20170411/a257821f9d1baa53e49e0b7074cb4f5a.jpg)
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oooooo I've always liked the idea of those headlights... and the looks too!!
I wonder how easy it is for oncoming people to see the signal when it's flashing. I bet there are some pics on google I can search for. Loving the updates moto!!!
Great work so far! This is going to be a nice one!
Please do keep us updated.
I got the frame back from the blaster yesterday, finally! And have been filling in nicks and pits with JB weld before it gets powder coated, this is the first time I've done this so fingers crossed it comes out ok! (https://uploads.tapatalk-cdn.com/20170414/720f71a99675137608496e8b84c5517c.jpg)
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looking gooooood :thumb:
i used to have a morgan garage directly opposite my house so there was always unusual cars about, kind of miss it actually. off topic haha but yeah hope you remembered to scrape the powder coating back off the mating surface for the disks :cheers: a lot of people forget.
with the 160, how are you planning to offset the front sprocket for chain clearance? the rear is easy enough with a big spacer but the gs has an awkward countershaft due to it using the circlip rather than nut. ( my bad if you've already mentioned it ) think my plans to drill and tap the end so i can shim it 3mm when i switch back to road tyres.
To be honest i hadn't considered it, from reading other people's experience they haven't needed too.
http://gstwins.com/gsboard/index.php?topic=25426.0
That being said I will see how it fits on the bike , if i need to i will made up a spacer on the lathe.
The previous owner of my bike welded on the front sprocket in their infinite wisdom. Idiot.
So I'm either going to have to rebuild the bottom end with a new output shaft, or get another engine, at which point I'll sort out the spacing issues, hopefully it all goes together nice and easy.
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Today I've made up the rear led light bucket for the sub frame, now I've just got to cut a slot in my nice new subframe.. :s(https://uploads.tapatalk-cdn.com/20170415/d14c5c4993159df85a3f5c3af87084e7.jpg)(https://uploads.tapatalk-cdn.com/20170415/4959a9a7829697aac06ec2acf0d26cb6.jpg)
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So I've committed to it, no going back now! (https://uploads.tapatalk-cdn.com/20170415/347b7c7f168a34af5de1a27e84625b5c.jpg)(https://uploads.tapatalk-cdn.com/20170415/f779b1e6c9bec9aefd24af2c61b14217.jpg)
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That's as far as I've got today.(https://uploads.tapatalk-cdn.com/20170415/c1475dde91c1245de2f9d794f8a7099c.jpg)(https://uploads.tapatalk-cdn.com/20170415/47aa6f8d6a63df015e3df39b935e162e.jpg)
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Bravo! Cogitomoto, eat your heart out!
Took quite some time to get right but it fits!(https://uploads.tapatalk-cdn.com/20170416/230f0448dd921f3663489e85f4facc6b.jpg)(https://uploads.tapatalk-cdn.com/20170416/c92cfae45d7e9c075966a8f421316357.jpg)(https://uploads.tapatalk-cdn.com/20170416/eff0baf6cf83f32601b95ea2f9389e36.jpg)
One side welded and filed down
(https://uploads.tapatalk-cdn.com/20170416/568bfaa4eb4e6ddecc583d99b20a77a2.jpg)
(https://uploads.tapatalk-cdn.com/20170416/78a9a9ef07b94264576e065cae1dd76d.jpg)
A bit of JB weld and some powder coat and it'll be good enough!(https://uploads.tapatalk-cdn.com/20170417/0ec2650760691701d69a3d72d3496189.jpg)(https://uploads.tapatalk-cdn.com/20170417/d1fff5411a7e48819bea841b0693b6d3.jpg)(https://uploads.tapatalk-cdn.com/20170417/3d90651e6819148d37c7b958295f2664.jpg)
(https://uploads.tapatalk-cdn.com/20170417/60c86622db98846db10176a8845c53be.jpg)
(https://uploads.tapatalk-cdn.com/20170417/35378b3c90177786860339761a1fedf1.jpg)
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:woohoo: :woohoo: :woohoo:
Looks very nice indeed :star:
That is cool as hell. Cant wait to see what it looks like with the bike all put together.
I do like that stop/brake light.
How you gonna attach the liscence plate and light though?
That's hot! Impressed you managed a cut that straight using a hacksaw and no jig!
QuoteImpressed you managed a cut that straight using a hacksaw and no jig!
I wish it had been straighter! hard work cutting a straight line on a curved bit of pipe, thankfully i have a big ol' file that straightened things up nicely.
I'm thinking about mount the plate like a ducati monster to keep the rear end clean, failing that I'll have to weld a plate to the underside of the subframe.(https://uploads.tapatalk-cdn.com/20170421/480a7b84f3b19832292f5dce6f064228.jpg)(https://uploads.tapatalk-cdn.com/20170421/fc8649ddec133c52ea6cf62f75aef5b2.jpg)
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I might just stitch a clear pocket into the back of my jacket for the plate so that I can keep the bike clean and shaved. :icon_lol:
What about building it into the back of the seat and fair it in with the seat? Depends on how big you plates are though.
Maybe something like this. Without the light fitting (https://uploads.tapatalk-cdn.com/20170422/6d063bd879014226b2fdcd4e6f3f2adc.jpg)(https://uploads.tapatalk-cdn.com/20170422/7059d4409f94312772222600334cc8a7.jpg)
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What's that actual size of the licence plate that has to go one?
As small as i can get it, i think probably 6x4" or 7x5"
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I see your problem with the plate size. Real parachutes. Even more reason to incorporate into the back of te seat area,I would think, rather than hang down. A little styling work and it could pretty well disappear from the side and still look OK.
Maybe the plate could go into the back of the seat but the plate light stay on the frame ( lit from the bottom).
It would be a shame to spoil the clean line you get from that brake/tail light.
Here we also have to have a 1 square inch reflector ( 600mm sq I think is the actual measurement). Consider 3M reflective tape beside the light if you have to add a reflector. It weight nothing. Lasts really well if applied properly. And you can get the total area you need easily. It has the advantage of reflecting from far greater off axis angles.
Or you can tuck the license plate deeper into the seat, and preserve the beautiful clean lines of that hoop.
Something like this?
(http://www.competitionwerkes.com/images/products/1B1000LTDangle.jpg)
Don't think those blinkers are gonna be real effective. In Aus they have to be a min of 300mm centre to centre anyway. The licence plate in Queensland has to be no more than 15deg from the verticle so we couldn't use that one. That's why I tend to incorporate it into the seat.
So the frame finally came back from the powder coater today!! It came out really well in a textured black black finish. Excited to get this bike built up now!!(https://uploads.tapatalk-cdn.com/20170426/dff009511493d05dbca28caec1b5fb6f.jpg)(https://uploads.tapatalk-cdn.com/20170426/69b850e4cbf1a3239bf66677ec902590.jpg)(https://uploads.tapatalk-cdn.com/20170426/396cf32b63c3b10a0172a05116c1f8f3.jpg)(https://uploads.tapatalk-cdn.com/20170426/35d68a0d080759cbfb53615d04e1a794.jpg)(https://uploads.tapatalk-cdn.com/20170426/e5b3975b1a610274576422424b372166.jpg)
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Going well. I really do like the rear subframe work.
:woohoo: Lookin' clean!!!
Coming together!(https://uploads.tapatalk-cdn.com/20170501/ea20b120721f2a18a53f2aacb756443c.jpg)(https://uploads.tapatalk-cdn.com/20170501/1e7e2ac6289db574185ce18d5eee73bb.jpg)
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Engine in!
(https://uploads.tapatalk-cdn.com/20170501/3e08e04d743a30a2567a1dd9a984cc85.jpg) (https://uploads.tapatalk-cdn.com/20170501/132cadd370e5e1ea75f4c9c7baeef9f2.jpg)
(https://uploads.tapatalk-cdn.com/20170501/84c1f322535e8166ff3db3984c5218df.jpg)
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That looks amazing! You've got some mad skills!
Think you'll powder coat that subframe, or leave it bare silver metal to show off your handiwork?
If you go with a K&N filter, it'll save some clutter and show off that nice tail better.
Thanks, im really happy with the way it is going!
I think im going to go with a gloss black on the rear sub frame, so it stands out against the Matt of the main frame, but is still subtle - ish! Ive got a little bit of welding and fettling to do with rear before it gets a coat of powder.
Ive got a lunch box filter on order, which should keep things clean, hopefully my R6 shock will turn up this week too! :woohoo:
You're gonna love the R6 shock. It's definitely one of the best upgrades I've done on my bike.
Having all that empty space in the tail makes pulling and installing a shock a whole lot easier. You'll prob have to grind out a bit of the swingarm though.
I posted a description as part of my signature link.
Our rides are built along very similar lines!
Any thoughts on your exhaust? I've got a suggestion... :D
I'm thinking one of these two:
(https://uploads.tapatalk-cdn.com/20170502/dd22a87e4f1fc718d635fc60602275e4.jpg)(https://uploads.tapatalk-cdn.com/20170502/84748acf2d92c5e6ee5450de5f71c571.jpg)
Or
(https://uploads.tapatalk-cdn.com/20170502/ba26b184d6f3cdeec995997c1996d714.jpg)
(https://uploads.tapatalk-cdn.com/20170502/84aca1fde65a86386ccace2d3deb6993.jpg)
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If you're asking for opinions, second one for sure.
Yea I think option 2 as well!
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R6 shock test fitted! (https://uploads.tapatalk-cdn.com/20170503/435cb1cf658b3a0c8eb3d162357a3073.jpg)
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Do work! Sweet!
Its a roller!!(https://uploads.tapatalk-cdn.com/20170509/793e3e2753f63a7a6f29269f35b0b94f.jpg)(https://uploads.tapatalk-cdn.com/20170509/7b2f46c0953fe9a8d3b60d8708a72cb3.jpg)(https://uploads.tapatalk-cdn.com/20170509/3b61e76e505c23b77ec7a519c5c9dc45.jpg)(https://uploads.tapatalk-cdn.com/20170509/7fa4209dc21a9b22d363740def13f6bd.jpg)
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Looking great, I have about 2 hours left to put mine together. It is not nearly as nice but I do not know how to do half the stuff you have done so far.
That tire is sexy
This thing is looking awesome.
Are you considering mounting the rear brake underneath the swingarm. Been considering that . Would be interested to see your approach.
The Conti's are very good road tyres. Didn't like em much for the track, but VERY good on the road, except in the very wet. Then the PR4's eat em for breakfast.
On a side note. What's the MTB on the wall. It looks like it has very old model Manitou froks , so a guess is a medium high end bike for the time.
No I'm going for standard placement on the brake calliper, keep things simple!! The mountain bike is my trusty old rock hopper! Needs some love though!
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So today I started work on the under tray, it's cut from 2.5mm aluminium that will be powder coated. I also had some tabs laser cut to weld onto the sub frame for fixing the tray too.
(https://uploads.tapatalk-cdn.com/20170520/9f3cda8e8fe1f50792311e1b5803685f.jpg)(https://uploads.tapatalk-cdn.com/20170520/5b0a6f07d696286225e3e66d87556f59.jpg)(https://uploads.tapatalk-cdn.com/20170520/aedee529c4aefa5cc30a217289291aa0.jpg)(https://uploads.tapatalk-cdn.com/20170520/05a6172adb3a8c68e7494478f5399584.jpg)
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Subframe plate is on!(https://uploads.tapatalk-cdn.com/20170522/824e7d46810d5f476193e630c033450e.jpg)(https://uploads.tapatalk-cdn.com/20170522/bc569071236fbd88bcd0a8f1fc36e421.jpg)(https://uploads.tapatalk-cdn.com/20170522/48ca07c545b84ee1b4f8ac63d3d57732.jpg)
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Looking good! Can't wait to see this build when it's all finished.
Thanks man, it taking longer than I wanted! Life keeps getting in the way!
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So my lovely lady caught me off guard when she said she was looking forward to getting on the back of it for some road trips... oh.
I hadn't considered a passenger getting on board, so I had been scratching my head about how to do passenger footpegs without ruining the subframe, until one day last week i got overtaken in traffic by a Honda cb 650f which had the perfect solution, bolt on arms for a tubular chassis.
A quick blast on eBay and a few days later they're here, and look pretty good! Just need to fab up some mounts then I can put them on when needed!(https://uploads.tapatalk-cdn.com/20170522/4f40412cc30cec30fd8847e97fa049dd.jpg)(https://uploads.tapatalk-cdn.com/20170522/103ef2f87cdedc33527496732054bb0a.jpg)(https://uploads.tapatalk-cdn.com/20170522/6619dd38e3b31e7fd6caacf7ab8e0069.jpg)(https://uploads.tapatalk-cdn.com/20170522/b7ae9c428af5848fc65e5b933e47a5e9.jpg)
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That's wonderful!!! I love when I get an idea for something just from looking at other bikes.
And no shame in a project taking longer than originally anticipated... I've been working on my car fix/restoration for almost 3 years now. If things are done right, they take time, patience, and attention to detail :thumb: That's the only way to do stuff!
Looking absolutely great moto :star: :star: :star:
" So my lovely lady caught me off guard when she said she was looking forward to getting on the back of it for some road trips... oh."
Alternate route. Get her her own bike?
Brat sidecar! I don't even know what that means, but you could invent a whole new genre! :cheers:
This weeks progress shots:(https://uploads.tapatalk-cdn.com/20170525/1a62a838934d40d32f6d50cd9c3dd3f8.jpg)(https://uploads.tapatalk-cdn.com/20170525/f803408d62a654b37ebd8cf2b0137b25.jpg)(https://uploads.tapatalk-cdn.com/20170525/e490e92f286c8b694786bfcc2e4a4090.jpg)(https://uploads.tapatalk-cdn.com/20170525/6566cbcd1f90b288c860f2eb77d509ba.jpg)
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This is looking amazing, really nice workmanship.
Quote from: moto on May 22, 2017, 01:34:42 PM
So my lovely lady caught me off guard when she said she was looking forward to getting on the back of it for some road trips... oh.
Can i ask where the battery is going? I imagined it was going under a fiberglass cowl at the rear of the seat but i guess not? It would be a real shame to have the battery on display for all to see and take away from the clean look of your machine.
Johno
Your bike looks amazing!
It's exactly what I had initially dreamed for my project, before it drifted in other directions. Really love that tail hoop.
Keep us updated
Sharp looking! What did you decide as for the little lady?
Quote from: Suzi Q on June 02, 2017, 07:25:17 PM
Sharp looking! What did you decide as for the little lady?
Foot pegs :D
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Today I got my rusty tank bracket stripped back to shiny metal and welded onto the subframe, it also has bolt fixings from the old frame which became the perfect place for mounting the stopcock! Win win! (https://uploads.tapatalk-cdn.com/20170603/63a3a62a8dc9c2943bbdfc0d0e9f175e.jpg)(https://uploads.tapatalk-cdn.com/20170603/62c1e8f940f76c73c0813fd36c24d16d.jpg)(https://uploads.tapatalk-cdn.com/20170603/52a49936cde81179a289ce9efa16db3c.jpg)(https://uploads.tapatalk-cdn.com/20170603/33d86eb2cfeb35a51a024bb27b85a09e.jpg)
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So having looked at the battery's available on the market they all seem to be over priced and too big for this project, so I'm building my own which will have the same power as a anti-gravity 4 cell but will have a much smaller profile. The bits have arrived, I'll post up my progress shortly!
(https://uploads.tapatalk-cdn.com/20170612/7e56b41fb951ffbfe1dd7b732061f7cb.jpg)
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Can you post up a how to while you're at it? I'm really interested in doing something similar.
So things you need:
100w broad tip soldering iron (this is important, you want the heat but you want it quick so you don't cook the battery cells, the broad tip does this well)
Solder
Flux (your soldering to aluminium)
Brillo pad scourer
Cotton buds/ qtips
Battery cells (A123)
Black tape / shrink wrap.
Battery Bars (small solder-able connections needed for the current drawn - could be made easily, I just found them cheap online)
4 guage black and red multistrand cable.
Volt meter.
1) check the battery voltages - First thing I did was make sure they were all the same, if they're not they need to be charge up so that they are, this makes life alot easier during the life of the battery.
2) flux and tin the battery Bars.
3) clean the cell ends that are to be soldered with the Brillo pad, this scuffs them up and makes them easier to solder.
4) flux and tin the cells, this needs to be done as quickly as possible to ensure that you don't cooks the cells.
5) line the cells up in series, positive to negative and solder them together. You need 4 cells to get to 12-13 Volts as they are 3.2v each. ( If you need more ampage then run a second set of 4 in parallel)
6) solder the battery bars to the cells.
7) solder the 4 gauge cable to the end positive and negative cells. ( This required alot of tinning of the cable to make the process quick and not cook the cells)
8) wrap the cells in tap or shrink-wrap.
9) solder a connector of your choosing to the cables. ( I used a 175a Anderson connector)
10) you can choose to install a set of balancing charger cables, I chose not to as all the cells are equally charger, and should stay that way when charged by the bike)
11) sit back and admire your handywork.
(https://uploads.tapatalk-cdn.com/20170612/61eebeae9902bf39069dc3183614c331.jpg)(https://uploads.tapatalk-cdn.com/20170612/4c0562b8af78530b3cb227506639e5de.jpg)(https://uploads.tapatalk-cdn.com/20170612/c6b08bc0582f9f0c50a2a2080f094a0c.jpg)(https://uploads.tapatalk-cdn.com/20170612/8dc5d49806ad6118fa533fbe832b70e4.jpg)(https://uploads.tapatalk-cdn.com/20170612/2668298c4174cd772633d7744885a897.jpg)(https://uploads.tapatalk-cdn.com/20170612/10088672842dcd17f18a58f5a2a15ffb.jpg)(https://uploads.tapatalk-cdn.com/20170612/da80929e490dafbb9d09d2989737540d.jpg)(https://uploads.tapatalk-cdn.com/20170612/f15a5d9dd0ad01e9d1b522cba425e905.jpg)(https://uploads.tapatalk-cdn.com/20170612/caf4933cd3891998488e08eb38432ff9.jpg)(https://uploads.tapatalk-cdn.com/20170612/7649de82ada656fc5827d971dd0c6add.jpg)(https://uploads.tapatalk-cdn.com/20170612/a664a6c7f67e093c4dbd259299c19ac7.jpg)(https://uploads.tapatalk-cdn.com/20170612/dd8a3360e0b5b254df77570ae82db0ff.jpg)(https://uploads.tapatalk-cdn.com/20170612/2d73eeda1dbb141fc469c3a26fa89286.jpg)(https://uploads.tapatalk-cdn.com/20170612/4110ef39cc931ad05c9315d02713418a.jpg)
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This is it installed on the bike. It's tiny. ;D
I also know it has some serious Juice as I accidentally touched both terminals together and it sent my arm into cramp for the best part of 10 minutes! I'll wire it up tomorrow and see how it does!(https://uploads.tapatalk-cdn.com/20170612/771e8621b76ecc11c86d8b5f470e8958.jpg)(https://uploads.tapatalk-cdn.com/20170612/ab0c6c51837d567afaddd517cd3cf352.jpg)
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Wow, very very cool!!! :cool:
Wow thats wicked, any idea on the cold cranking amps?
It should be about 120 amps
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More goodies arrived today :woohoo:!(https://uploads.tapatalk-cdn.com/20170613/9b16bf705c14c9f93f6efc0bf389be24.jpg)
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Why can't they come out of the factory like this?
No way I'd ever be able to make this.
can't wait to see the end result.
Thanks Toner, it's getting there!
I also got the bike wired up in a temporary state last night, happy to say that the built battery turns the bike over with ease! Happy days! :woohoo:
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Please build and sell those batteries, I will be first in line to buy one.... GREAT thread and good luck continuing the AWESOME work.
i've toyed with the idea of making batteries up for projects in the past and it's damn cool to see someone actually following through with it. solid work as always moto :thumb: :cheers:
So this evening I finally got the seat base cut out of 9mm ply, it's really starting to take shape now and you can see the thin profile of the rear. All of the electrics including the battery are under the seat base or under the tank! Just needs foam and upholstery and we're almost there!(https://uploads.tapatalk-cdn.com/20170621/cf38173784841a60d2b4e6c8b1f0f670.jpg)(https://uploads.tapatalk-cdn.com/20170621/5d8eb1f414640ab012a925d8ab7060bd.jpg)(https://uploads.tapatalk-cdn.com/20170621/506fc5c9f0d1bba849a3694794f72f29.jpg)(https://uploads.tapatalk-cdn.com/20170621/046db4a491f574a30feb83cee1b16367.jpg)(https://uploads.tapatalk-cdn.com/20170621/fa60535e920e872a6ca893c04ac71451.jpg)
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Looking good so far, mate. What kind of seat are you planning?
Something along the lines of these without the kick, but I'm really torn on the colour with the light beige tank.(https://uploads.tapatalk-cdn.com/20170623/3158c4f28abcb3fa3739af153e0a0519.jpg)(https://uploads.tapatalk-cdn.com/20170623/71206992dac425ffd17b2c041b446a99.jpg)(https://uploads.tapatalk-cdn.com/20170623/33709d1882c3690afe114cb6be459356.jpg)(https://uploads.tapatalk-cdn.com/20170623/714d6d6bcdf99c9909cad74d1d998f97.jpg)(https://uploads.tapatalk-cdn.com/20170623/1391a591f0398d6316f5a133a1aa64f2.jpg)(https://uploads.tapatalk-cdn.com/20170623/46517aa6851dfdfe98fd50f62cfe0bdb.jpg)
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I've had a quick Photoshop.. what do you guys think?
(https://uploads.tapatalk-cdn.com/20170627/8af2882f09f0a14f338aebeee7177153.jpg)(https://uploads.tapatalk-cdn.com/20170627/aee8f73b3d65b85b7add747ed14ce513.jpg)(https://uploads.tapatalk-cdn.com/20170627/9418630917ee2547087a3a73bfa86dab.jpg)
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I think it needs a hump. Maybe a glass tail that you could take off when you take ya miss' out?
I personally like the second image, the light brown one. However a hump may look good as well. One like this
http://www.ebay.com/itm/Hump-Universal-Cafe-Racer-Seat-Vintage-Saddle-for-Honda-CB-GB-XL-Yamaha-SR-XJ-GS/231976657885?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2055119.m1438.l2649
I'll have a look at a fibreglass shroud as a later step I think, something like the ones on the triumph thruxtons
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They all look awesome so that makes it tough for me to choose but I'm gonna go with 89gS500_Kirk on this one... I like the second pic as well :thumb:
I was adamant that I wouldn't build another cafe racer.. but you guys are right about the removable rear hump.. damn it! :technical:
(https://uploads.tapatalk-cdn.com/20170628/77f3a7ccf41c3cc4cd344d0210690d56.jpg)
(https://uploads.tapatalk-cdn.com/20170628/fc24ff0eb929ac7d06e3c122e5295c7a.jpg)
(https://uploads.tapatalk-cdn.com/20170628/32fd223570d68328eb82752e12ac3be9.jpg)
(https://uploads.tapatalk-cdn.com/20170628/4d614cc1433bd14b23c34e4e4752ee8c.jpg)
(https://uploads.tapatalk-cdn.com/20170628/64d05ee411d03b48e7cd6cc822ed1368.jpg)
(https://uploads.tapatalk-cdn.com/20170628/8b2cfe1324522b4702b0e82c754e8be3.jpg)
I think I'm leaning towards the red with the rear hump, as it's a little different!
I'm also looking at a hex stitched seat which could be quirky, adding a modern touch to a classic style. (https://uploads.tapatalk-cdn.com/20170628/93abc96aaacbc6a84be9e95ce4c221c7.jpg)
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I like the red, as it matches with the shock spring. Rear hump is also cool, might be nice to have. And if you don't like it, you can always just remove it lol.
I really like the hex stitching and that red seat looks good with the hump. However if you are set on a certain style you can always add the hump on later or remove it, that's the fun part. The bike is looking awesome keep up the great work.
The exhaust turned up today! Can't wait to get this thing running now!(https://uploads.tapatalk-cdn.com/20170628/393a7ddc3ec394ce845862eaa82c6303.jpg)
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One other thing I'd like to mention: your photoshop skills are pretty good. Adding in the reflection on the rear hump is a nice touch, makes the concept look more real.
I had the same dilemma on my build, trying to figure out how to get that cafe racer seat look right.
Fashioning a proper seat cowl was tougher than I could manage. Finally went with the Ducati seat.
I'm sure that whatever you end up choosing, it'll be awesome.
Though nothing is permanent... mine is set up so I can swap out seats depending on what mood I'm in :D
Thanks qcbaker, it was a quick 10 minute job on my lunch break, its great what you pick up living with automotive designers at uni!
I fibreglassed up a seat unit before on my previous CB200 build, but it is a long winded process to do it right! ive been looking at buying a seat hump from the states, but it wont be a perfect fit out the box and would need some glass work to get it right.
http://www.ebay.com/itm/Cafe-Racer-Removable-Seat-Cowl-Hump-CB550-CB750-CB350-Brat-Style-Yamaha-Honda-/222530397796?var=&hash=item33cfd86664:m:mgP_0w0oEKbjnQp83FZx9tA
I think I might make a buck up and do some getto vaccum forming at home! :woohoo:
http://www.instructables.com/id/Make-a-good%2C-cheap%2C-upgradeable-sheet-plastic-vacu/
Caution with that eBay item. I bought something like that and was very much disappointed.
Took forever to ship over, and for all that money it was a flimsy piece of plastic.
If you're planning on using it as a base mold or something, it'll be OK. Else on its own, it'll be way below the quality standard you've shown so far on your bike.
The engine needs a tune up but here it is! the first time it's run since I bought it as a basket case!! It's also running off the 4 cell battery :D :D
https://drive.google.com/file/d/0B2qDOT8TlpLcU1E3NklIWjRVN1E/view?usp=drivesdk
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That's where I've got to as well. They quoted $80 for a bit of vacuumed formed plastic and another $50 for shipping to the UK.. it's a bit of plastic!! :o
For £100 I'll be able to make a bespoke item that fits perfectly, its a no brainer.
Watch this space!
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I really like that battery idea. Are those 18650 cells? Wonder if they are available with solder tabs spot-welded. I'm never comfortable heating a lithium-type battery enough to solder to it directly. But those cells would make killer bicycle light batteries and the ability to charge them with a conventional lead-acid charger is brilliant.
Anyway, I think I'll put this on my to-do list, whip up a new tiny battery for my GS. Then I could hide the R/R, relays and igniter all within the space of the original battery and get rid of the side plastics without unsightly junk showing through.
They're a123 nanophosphate anr26650 ml- B cells... Not really sure what much of that means, but they work like a charm and seem to be very resilient to heat.
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Thanks for the clarification. I know approximately what that stuff means :) I looked on A123's web site, they only offer two cells, the 18650 and 26650 cells. There are other vendors of the same chemistry cells in 26650 form factor so I may see about picking up a set. Maybe I can find them with solder tabs and make my job much easier.
:thumb: :thumb: :thumb:
EDIT:
BTW here are LiFePO4 26650 cells available with tabs:
http://www.batteryspace.com/lifepo4-26650-rechargeable-cell-3-2v-3300-mah-19-8a-rate-10wh---un38-3-passed-ndgr.aspx
The tabs makes soldering them basically trivial. You can actually butt the cells back to back or side to side and just fill solder between tabs, using an ordinary 25W soldering iron, and it doesn't risk damaging the cells with heat, which is nearly guaranteed if you are trying to solder directly to the cell. $30 for four cells and you're in business here.
Just an FYI for those following along. I'm going to keep searching for myself.
I've had another play on Photoshop at lunch, I think I'm going to make the hump replicate the shape of the tank to carry on the Suzuki design cues
(https://uploads.tapatalk-cdn.com/20170630/5e21aaf09de112008c55a0008fe08db1.jpg)
(https://uploads.tapatalk-cdn.com/20170630/a05b08b72484afb24d631e7afef8d518.jpg)
(https://uploads.tapatalk-cdn.com/20170630/21c196f5d4ff161afaed26d6417d3538.jpg)
Since you are adding the hump to the seat will you leave the rear pegs off now? IMO I like the look without the rear pegs, however I never ride double. Great build as always
im still looking to install the passenger pegs as one of them will be acting as an exhaust mount point for the new system.
In fact... Welded on the brackets this evening (https://uploads.tapatalk-cdn.com/20170630/4c8ebe881e367d996dbdbef037707fac.jpg)(https://uploads.tapatalk-cdn.com/20170630/e3b191f6be526d3d67f6e51170ce615f.jpg)
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I like the brown and hump. Looks very classic. I also like the red hex and hump . Very classy!
Just a note . Are you sure that that gauge tube will hold a passenger. It looks like it will bend at the weld junction with the lower struts once weight of a passenger is put out at that much leverage.
You could redo you seat base to be structural, which would help ( carbon fibre?). It would end up deeper but hopefully be stronger and stiffer with double load weight, without making it too chunky looking with careful design.
The steel tube that was used to form the seat hoop is 1" 12 gauge, so pretty thick walled stuff - with the cross struts as well its not moving anywhere, it would take a lot of load to bend the frame, and I think the suspension would have to give way first :laugh: that and the fact that her ladyship is dinky I hopefully wont have a problem :) The proof will be in the use!
It looked narrower diameter in the photos. 25mm/2mm should be reasonably stiff. The weld will soften it a bit but could be fine at that size.
I've been away for a couple of weeks, but today I got the seat foam cut and stuck down, we'll see how this fairs!
It's give an idea of what it's going to look like, starting to come together!
(https://uploads.tapatalk-cdn.com/20170709/7b950450295c2113f1ebec1894f74d78.jpg)(https://uploads.tapatalk-cdn.com/20170709/3746240477ca1beb6864a0dd3c3cd392.jpg)(https://uploads.tapatalk-cdn.com/20170709/7d59a804b6d8446ac084b24b7d6fabe7.jpg)
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Today I got the frame back from the powder coater so got it on there this evening.
(https://uploads.tapatalk-cdn.com/20170713/86d4114ad3c3730f4910f4e4a7e04240.jpg)(https://uploads.tapatalk-cdn.com/20170713/487b5bfe852e5e4319dacc6f23e591fb.jpg)(https://uploads.tapatalk-cdn.com/20170713/bd74ad17b10d79644f565e4c944f3409.jpg)(https://uploads.tapatalk-cdn.com/20170713/7457dd66da6c13bda9fe180f9aeb0339.jpg)
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Looking very good!
Before I send the seat pad off to be upholstered I wanted to get a start on the seat hump just incase any tweaks and adjustments are needed. So here it is:
The first thing to do was to create a former of the seat foam so it is a good fit from fibreglass, this was done by wrapping the seat in masking tape then in ducktape for good coverage, you don't want the resin to touch the foam as it can melt it.
(https://uploads.tapatalk-cdn.com/20170715/dc61e4e48528b2cc9ed99a49a5f68c5b.jpg)
Then the tape is covered in bees wax and sprayed with hairspray ( cheaper the better!) To act as a releasing agent.
(https://uploads.tapatalk-cdn.com/20170715/dea0287cc2c713eb754fed298e712974.jpg)
Then it is a simple case of laying up some fibreglass and resin - at this point it's not really a concern about the final finish, this is only the very beginning of make a mould buck. I did two layer of course matting.
(https://uploads.tapatalk-cdn.com/20170715/a78576d572a448b6488e5f4cc8680b73.jpg)(https://uploads.tapatalk-cdn.com/20170715/75570f8c7286e9f3727b2495895b8491.jpg)(https://uploads.tapatalk-cdn.com/20170715/afe3ca7331bb08aab25173e942b8af76.jpg)
Once dry it's time for a trim up with the Dremel.
(https://uploads.tapatalk-cdn.com/20170715/92a95a8c9b680a3cb0ca89c13db06deb.jpg)
(https://uploads.tapatalk-cdn.com/20170715/976fd416f20bdd8da8e42dc661b2cc64.jpg)(https://uploads.tapatalk-cdn.com/20170715/942bee18669ab504ad3be4a38fb6aad9.jpg)
One of the hardest thing about making and modeling anything is keeping it even on both sides, to help me with this I made up a very rough model in SketchUp that I then sliced up to make help make a formwork for the hump:
(https://uploads.tapatalk-cdn.com/20170715/c40c2b9f227e6bf6ddfd3b2976e5babf.jpg)
(https://uploads.tapatalk-cdn.com/20170715/adaa068450f10a5ce3ca4ec379e5cfa8.jpg)
(https://uploads.tapatalk-cdn.com/20170715/d54f4ca00a32623070faffa582c9d838.jpg)
These are then printed off, stuck to card, cut out and stuck to the base to create a 3D formwork, basically go mental with a glue gun, card and match sticks, it's great as you start to get an idea of what it's going to look like!
(https://uploads.tapatalk-cdn.com/20170715/74e06c72cc5bf2b342314b7c4a2038f3.jpg)
(https://uploads.tapatalk-cdn.com/20170715/4b4c8ecf87ef625356cec2605205d652.jpg)
(https://uploads.tapatalk-cdn.com/20170715/25c252c47d47c726e910d70734523be2.jpg)
(https://uploads.tapatalk-cdn.com/20170715/c9600175a01578a066a65cc5e6d70e55.jpg)
(https://uploads.tapatalk-cdn.com/20170715/d682b0e00899081c652c7a5e5eb0cb79.jpg)
(https://uploads.tapatalk-cdn.com/20170715/f446de2471df7c0d64fc404da7d19bcc.jpg)
To get this to become a more solid structure the first step is to pump it full of expanding foam
(https://uploads.tapatalk-cdn.com/20170715/329f2a452d33b8aa57f97aaac5336c32.jpg)
(https://uploads.tapatalk-cdn.com/20170715/cc3bc2cabbd53e8c683f96f554a81601.jpg)
The next stage is to cover the foam in filler once dry and get to work - cue hours of sanding and filling and sanding and filling and sanding, painting, 2 part mould making and finally producing a seat hump!.. more to come!
First stage shaping complete,best to use a bendy knife to help form the curves.
(https://uploads.tapatalk-cdn.com/20170715/47b0825cff7f840a8a36d64f4a434fbd.jpg)
(https://uploads.tapatalk-cdn.com/20170715/6d6d2628619e289c6e496e4f4f6c7908.jpg)
(https://uploads.tapatalk-cdn.com/20170715/157afe8102e66f8e5fddb77be1c454cb.jpg)
(https://uploads.tapatalk-cdn.com/20170715/5d429e7818c1145505c90ec8b8cca0e1.jpg)
Here's the first round of filling, as it's just mould buck there is no point in using expensive body filler, so for the basic shaping I'm using plaster filler, cheap and very easy to work!
(https://uploads.tapatalk-cdn.com/20170715/4b3c1e46af1dac24cfd4b6183252576a.jpg)
Icing the cake!
(https://uploads.tapatalk-cdn.com/20170715/c7c5af6d3d9b605f07360e6b8894a704.jpg)
Few coats of filler and we have this:
(https://uploads.tapatalk-cdn.com/20170716/bbfd8c377122d0f023bc745ae0c0dd6f.jpg)
Marking up the relief cuts:
(https://uploads.tapatalk-cdn.com/20170716/1b758cedf09b8e80722e7400e2cfd928.jpg)
(https://uploads.tapatalk-cdn.com/20170716/ecc32df909ada595079a394a9bd4f980.jpg)
(https://uploads.tapatalk-cdn.com/20170716/402d7ff628c268b4892175ab456d64ea.jpg)
It needs a load more work to blend it in better, but you get the idea.
(https://uploads.tapatalk-cdn.com/20170716/a627a6f9cb18bde1006a2843180ff795.jpg)
A bit more blending and filling.
(https://uploads.tapatalk-cdn.com/20170717/e0d7d9ce23880581a8925b6580df85c9.jpg)
That is so wickedly cool! You are a multi-talented artist! :woohoo:
Glad you're going with a race hump - it looks great. The flat seat alone looks great, but having a curved tail really complements the lines from the gas tank.
Sign me up if you ever go into business making GS seats!
Thanks Endopotential, this build is great fun! I'm happy I've done it now too, hopefully it should look good when it's finished!
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I'm always in the mood for a good fiberglass bit of a thread! Awesome job!!! Makes my mould that I made a while back for a seat cowl look very primitive, for sure.
Your posts will certainly be inspiration for others who search, I just know it! :cheers:
Wow! I am really impressed. Great work.
It's been a while since I've posted, life and work have gotten in the way of me finishing the bike off!
I made a bit more progress this weekend with some more sanding and filling, I also shot ALOT of high build primer on it last night to get the smoothing process going properly! It's getting there.(https://uploads.tapatalk-cdn.com/20170918/e877f6a55ad69f20dc9d686bedbe6775.jpg)(https://uploads.tapatalk-cdn.com/20170918/30d3f4334594286629113aede2bc4c24.jpg)(https://uploads.tapatalk-cdn.com/20170918/65f634ce1a27eb34d8855169fea1f002.jpg)(https://uploads.tapatalk-cdn.com/20170918/e292eaadc673064db70df7dacf41ec1b.jpg)
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High build primer is my friend. Looking sweet
Absolutely loved reading through this build! I have just impulse bought a GS500 on ebay which I'll be picking up this weekend. My first bike which will need alot of TLC. Your build is massive inspiration!! Thank you!!
Thanks Mrgaru! If you've bought a GS you've come to right place!
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So I've been filling and priming this buck for quite some time now :-\
It's only when you get it into primer and get a consistent finish that you can see what your actually dealing with!
You can see from the first photo that the recesses dont quite match.. damn. Being a bit of perfectionist and knowing that it will wind me up I'm going to have to re do it.. cue the Dremel cutting disk and a ton more filler! (https://uploads.tapatalk-cdn.com/20170923/07fa12c8e55679975f0a3fb1dfcbaf2e.jpg)
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This shows the difference(https://uploads.tapatalk-cdn.com/20170923/418865a6b103568afa4b191a7158045d.jpg)
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And here is the aftermath from the Dremel, good job I bought a massive tub of filler!(https://uploads.tapatalk-cdn.com/20170923/18c863363e5856e7f2a2c0ccc78b3c36.jpg)(https://uploads.tapatalk-cdn.com/20170923/6bbced8cf48fab9755a19acff9485aaf.jpg)(https://uploads.tapatalk-cdn.com/20170923/0b29bdec1d5d018a3e4ed1618414a936.jpg)
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That thing you did in sketchup, breaking it into slices, was that a plugin? I always thought about doing exactly this in sketchup for my front fairing instead of using a body panel gauge...
I used a Plugin called Slicer, it did a pretty good job!.
https://sketchucation.com/pluginstore?pln=TIG_Slicer
Awesome, love how you spend so much work for the details and even rework the "done" thing.
Thanks Ne0n its the details that make it, and that seat would have driven me insane 😂
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Today I got the seat buck painted in gloss black, this allows you to see all the imperfections but also seals the surface, so I'll give this a wetsand once it's dry, polish it up and then we can start laying up some fibreglass :D (https://uploads.tapatalk-cdn.com/20170930/8adef7e151edb474e133b9564075db0d.jpg)(https://uploads.tapatalk-cdn.com/20170930/0fed6d6caa3488b66318d6e5e4344454.jpg)
Looking good!
For the front of the seat, create a little fiberglass tongue between the seat and the tank, just to close up the gap. I learned this when I did my seat.
otherwise, water gets in between the tank and seat.
More goodies arrived yesterday, fully refurbished rear caliper and new pads, one of the last missing pieces! Just need to get my gauges sorted out, seat finished and upholstered and we're almost there!(https://uploads.tapatalk-cdn.com/20171001/70d98c2c58c4f30fd22a7c8ea694ecca.jpg)
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Slow progress on the mould, but I got the buck out of the shed and the paint went on really well, I'm not going to bother wet sanding it, it doesn't need to be perfect as I'm not laying up carbon fibre and there will definitely be some final finishing, high build primer and paint going on the final parts! No point wasting time!
I've started by giving the buck 3 coats of simple bees wax to provide a protective layer, you can buy expensive mould release wax but I've found this to be just as effective for DIY jobs. This will be followed up with more wax and a number of coats of hairspray to give a good mould release.
(https://uploads.tapatalk-cdn.com/20171004/fff3934bf2bf535445def98a0ffa07ec.jpg)(https://uploads.tapatalk-cdn.com/20171004/44ad9b793ec5fd6757b1e369887ed68b.jpg)(https://uploads.tapatalk-cdn.com/20171004/62b0f7f940bd67966db3360a801308c2.jpg)(https://uploads.tapatalk-cdn.com/20171004/8bc711a201a4132db0452802b22e44c0.jpg)(https://uploads.tapatalk-cdn.com/20171004/ef467c5e9a5ec7968714a09e74c0e954.jpg)
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The next stage is to create a central dividing spine, this mould is going to have to be a two piece mould due to the complexity of the side recesses, this means the mould needs to be laid up in two parts. The spine is a piece of card cut to the profile of the buck then glued to it with hot glue. Once the first side is laid up you can then tear out the spine, remove the hot glue and rewax the whole lot before laying up the other side to complete the mould.
Any gaps and bumps can be filled in with a wax based clay, I have also used this to smooth any very minor imperfections. The wax can be softened up with heat and thinned by mixing and folding some of the creamy wax into it. (https://uploads.tapatalk-cdn.com/20171004/bd5ca296eb1a8cb6e8d03f1f1ad6e38d.jpg)(https://uploads.tapatalk-cdn.com/20171004/354af7af26a9c10688842eb0c39d90dd.jpg)(https://uploads.tapatalk-cdn.com/20171004/f1752d43f44f7c76983b0229f5a5a883.jpg)
Gel coat on(https://uploads.tapatalk-cdn.com/20171010/c4384205fcd8612b1d0f12311b1bd9c4.jpg)(https://uploads.tapatalk-cdn.com/20171010/020f1cabad7b3ea125a565acb35082fb.jpg)
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Side 1 laid up with fibre glass(https://uploads.tapatalk-cdn.com/20171010/67923798dfd3039a1c2703526c533c14.jpg)(https://uploads.tapatalk-cdn.com/20171010/5b88e2ae1b605a776d01a6caa0d2d57a.jpg)
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Awesome thread! Quality craftsmanship. I look forward to seeing more progress. :cheers:
(http://www.reactiongifs.com/r/mwcpopcorn.gif)
Quote from: cbrfxr67 on October 11, 2017, 07:12:14 AM
(http://www.reactiongifs.com/r/mwcpopcorn.gif)
me too haha
So I made a boo boo with this one, I couldn't get the mould release due to the recess in the front and the back 🤦
Out comes the Dremel again, and off comes the front of the mould! 2 steps forward 1 step back.
So now we're making a 3 piece mould! Woop woop(https://uploads.tapatalk-cdn.com/20171014/f474a39610b42255ee4b580f58691b53.jpg)(https://uploads.tapatalk-cdn.com/20171014/02429ee943b0da67a16f58a9bcd84413.jpg)
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New divider added, I will get this finish at some point !(https://uploads.tapatalk-cdn.com/20171014/e71efe87f6190627ecd6ed2061d571a9.jpg)(https://uploads.tapatalk-cdn.com/20171014/2e8eab0dda30068b8a80f875b3165cd5.jpg)
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(https://uploads.tapatalk-cdn.com/20171014/d33390fbbf690f96414ca4ac2acabe7c.jpg)
Last of the mould gelcoat.(https://uploads.tapatalk-cdn.com/20171015/4da2cc0cf6c6915093457c55792981d3.jpg)(https://uploads.tapatalk-cdn.com/20171015/fe66ce20cc3e5d65d727dfb58c0d0ed5.jpg)
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Annnddd the mould is finished. Almost there!(https://uploads.tapatalk-cdn.com/20171017/2a5e4a49b8b43563e1973905a21cfff3.jpg)
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You are one of the most patient and diligent people I have seen. Good work! Thanks for keeping us posted.
Thanks ajensen, it's taking a while, but I would rather get it right!!
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Mould waxed up good, gelcoated, and laid up!! Fingers crossed this beauty releases from the mould 😂(https://uploads.tapatalk-cdn.com/20171019/38af7469fa008d6d4ab79dfe5ea4977f.jpg)(https://uploads.tapatalk-cdn.com/20171019/c98843abbbd621b806db0582bc485e65.jpg)
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And here is the part fresh out of the mould! Need need a trim and final finish but it's almost there!(https://uploads.tapatalk-cdn.com/20171020/bb853556eed545558082a89009c29262.jpg)(https://uploads.tapatalk-cdn.com/20171020/4ad240accdcd822660aca0afb618f359.jpg)(https://uploads.tapatalk-cdn.com/20171020/6686898b50ba3c8b75bcb3db0186732c.jpg)
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I am eager to see everything complete. Most of us are content to buy stuff off the shelf and are unable or unwilling to build what we really want. Good workmanship!
So here it is with the first trim up and test fit! Needs quite a bit more work but it's progress!(https://uploads.tapatalk-cdn.com/20171022/bf1d4979ed832228e24d1c2bb177b9c2.jpg)
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How is the exhaust slip-on supported?
Cool! Keep those pictures coming.
I've got to weld a tab onto the offside passenger footpeg, which will allow the support bracket to be fixed. But I'm looking at another option at the moment..
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So now it's coming together I'm not convinced the exhaust system suites the bike due to the way it sweeps up, I want to try and keep it as clean as possible. So I was looking at options and love the way some bikes keep the system under the belly of the frame (panagalie, ER6 etc). I'm a little concerned about ground clearance as the GS is pretty low, but I've bought a very clean ER6 exhaust to play with. If I can get it to mount well (looking to use the old centre stand brackets under the frame) and maintain adequate ground clearance I'll get some new down pipes made up, gut the can and run that 😁(https://uploads.tapatalk-cdn.com/20171023/4f79de2be56fac2e633a4c1558f50b34.jpg)(https://uploads.tapatalk-cdn.com/20171023/f3a8a270e4c04faaffaf41d06d34e4d8.jpg)(https://uploads.tapatalk-cdn.com/20171023/009043099caecf6ccc3afe06be0e8243.jpg)
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I got an underbelly planned too. but I need to do more re-search on sound dampening mechanics. IE what baffles are gonna give me the most bang for their buck at their current size.
Can we get an update PLEASE? I really have enjoyed your build and have been looking forward to updates.
Yes need updates! :icon_mrgreen:
Updates coming soon guys, sorry about disappearing for so long!
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Quote from: moto on May 28, 2018, 09:16:41 AM
Updates coming soon guys, sorry about disappearing for so long!
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Yes!
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So a long overdue update. I am currently rebuilding the engine, to deal with the welded sprocket, in the mean time I am getting parts ordered to finished up the project. I have decided on the seat finish, I am going for a subtle finish, black hex stiched suede and leather side panels, can't wait to see it finished, i figure if and when I want to change the colour of the tank a black seat will pretty much go with anything!
(https://uploads.tapatalk-cdn.com/20180716/14624af1999f3ba1381979d8d5652335.jpg)
I've also bought the gauges which will be turning up this week. Daytona Velona Dark multifunction guage that does Speedo and tach. It also comes with a cable that goes straight into the GS Speedo drive on the axle 👌
(https://uploads.tapatalk-cdn.com/20180716/9d3c499b7170971dc9f1163a2c5b1f26.jpg)
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Today I started work on the horrendous looking top yoke, I'm relocating the ignition, then making a bracket up to fit the guage where the key is. It will mount off the ignition bolt mount points.
(https://uploads.tapatalk-cdn.com/20180719/7b67aa9cf2e5ad0ac4550f36cbef675d.jpg)
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(https://uploads.tapatalk-cdn.com/20180719/03bf2bcc6cb2bba3b957c5a400da6787.jpg)(https://uploads.tapatalk-cdn.com/20180719/07f98f82c94e63de71ff7fb39bb26962.jpg)
rocking!(https://www.motohouston.com/forums/images/smilies/headbang.gif)
Pretty happy with that! I've carved out most of the yoke weirdness, just need to fill in the rest, then I'll hit it with some expoxy primer and paint (https://uploads.tapatalk-cdn.com/20180719/7edae45283d127e986e65c182f8cbd36.jpg)(https://uploads.tapatalk-cdn.com/20180719/4aebcb26569f8dd539ef5a0db34cecb4.jpg)(https://uploads.tapatalk-cdn.com/20180719/c1eea04d670ee4f4d01a9ddaad7cf577.jpg)(https://uploads.tapatalk-cdn.com/20180719/ec1cc55dfc37165fded577aa1287a0b7.jpg)
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I don't have an ac Tig welder so cant weld ally at home, figure it's a "non moving / flexing" part so I've filled the voids with 1p coins and epoxy 😅👌 we'll see if it lasts. A very light skin of filler and a good coat of epoxy and we should be good!
(https://uploads.tapatalk-cdn.com/20180719/12be4a3e836ce65d9a2ec1b42fe81f57.jpg)(https://uploads.tapatalk-cdn.com/20180719/675a4de9a70dff62a0d044af62350c4c.jpg)
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Looks good moto, I did exactly the same thing to my top plate. But i made and aluminum plate to cover the top. Also stripped the ignition barrel and cut the circle bit out.
Blended out and ready for some epoxy primer.
(https://uploads.tapatalk-cdn.com/20180720/9cd66d95efcb1348554f5f42a22da135.jpg)(https://uploads.tapatalk-cdn.com/20180720/286a32823f5f7d27e872c3e2f419c2f0.jpg)(https://uploads.tapatalk-cdn.com/20180720/547a5ce87f1902512376250ca703b195.jpg)
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Parts epoxied ready for 2k primer base and clear :)
(https://uploads.tapatalk-cdn.com/20180722/b505a909d55fda4914f4415b39def9b0.jpg)
nice job! :bstar: :bstar: :bstar:
Gauge cluster and top yoke all finished up ready to be fitted 😀
(https://uploads.tapatalk-cdn.com/20180726/dcdc47677dfc547ed020061017ce5f21.jpg)(https://uploads.tapatalk-cdn.com/20180726/5d3127779dc789161b1df1c97a7bcc7d.jpg)(https://uploads.tapatalk-cdn.com/20180726/1473506a07608c4079da0625afd97f8e.jpg)
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Engine parts clear coated ready for a cut and polish once cured.
(https://uploads.tapatalk-cdn.com/20180726/fb06a4a4115fdc2f277cdb60909656b1.jpg)(https://uploads.tapatalk-cdn.com/20180726/9664a7cacbf4d158eccc76ea1d42428e.jpg)
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Super nice, moto! My OCD approves of your work lol :thumb:
Thanks showbizwolf! :) here are the engine cases cut and polished ready for replacement during tomorrow's planned output shaft surgery 😷(https://uploads.tapatalk-cdn.com/20180726/53d17f13aee3ea759a3e7f6cccc3568d.jpg)
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New gauge pod fitted and engine back in with the new output shaft (https://uploads.tapatalk-cdn.com/20180804/8a447f38e8a881ec2d44f0013ecf48a0.jpg)(https://uploads.tapatalk-cdn.com/20180804/e4e9a5489394001c784c35f91c214f2d.jpg)(https://uploads.tapatalk-cdn.com/20180804/5e26c39c93bcb6705c3e2bf862490f95.jpg)
And the ignition barrel relocated
(https://uploads.tapatalk-cdn.com/20180804/4413218d83b8d92549f43df46379e09d.jpg)(https://uploads.tapatalk-cdn.com/20180804/e5ce2c13cc5e14452824ad54ce0a5636.jpg)
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That ignition switch is in that exact same location on my Yamaha scr/n=bolt and I find it annoying as the dickens.
Cool.
Buddha.
Really? Why's that? It's the only place I could find that wouldn't bash into my legs 😂
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New seat cover on its way back from the upholsters 😁
(https://uploads.tapatalk-cdn.com/20180813/81a50cb27c71beb628fef42ec3f1668f.jpg)
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Ready to be fitted
(https://uploads.tapatalk-cdn.com/20180819/1c9cedba854a1a580ee97ea44cd2eb29.jpg)(https://uploads.tapatalk-cdn.com/20180819/97f6d5c73e01c2c5c275a80e367bab78.jpg)
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I really like the look of that seat, can't wait to see it mounted.
Great seat :star: :star:
Not the best photos but it's almost there.
(https://uploads.tapatalk-cdn.com/20180820/4c7a6b3c86846bda81b6c03ef6bb791c.jpg)
(https://uploads.tapatalk-cdn.com/20180820/23f159f12e7ecbca5c5885ab0411b6bc.jpg)
(https://uploads.tapatalk-cdn.com/20180820/c65116b04eb4c4d33764a63a812f2874.jpg)
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And a couple more
(https://uploads.tapatalk-cdn.com/20180820/d719934255fb5b6c4abd8285b383d382.jpg)
(https://uploads.tapatalk-cdn.com/20180820/d4d509cb044e19509ccc859a8e5d30b9.jpg)
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sweee-eeet what's next?
Behold! The horendousness of a legal size UK number plate.. won't be that size for long though 😏
(https://uploads.tapatalk-cdn.com/20180820/100ad2aa1462b8826265da679fb440af.jpg)
(https://uploads.tapatalk-cdn.com/20180820/82cbb0dbe8821075964ea6aaea5b3483.jpg)
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Next thing on the list really is to wire everything up, get it MOT tested and enjoy riding it into the autumn :) I'm going to build a new engine this winter for it.
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I have a bit of a technical issue. The Daytona guage that I bought came with a Suzuki gs500f "ready" speedo drive cable. Converting the analogue signal to digital.. however it doesn't fit in my gs500 speedo drive on the forks.
The GS500 speedo drive appears to be 15mm, but the unit I have is 18mm. Were the speedo drive cables different on the gs500 and gs500f?
I don't know. I do know that in the later gs500f's the tachometer became electronic. From 2003 onwards, I believe.
Quote from: moto on August 20, 2018, 12:24:10 PM
Behold! The horendousness of a legal UK number plate.. won't be there for long though 😏
(https://uploads.tapatalk-cdn.com/20180820/100ad2aa1462b8826265da679fb440af.jpg)
(https://uploads.tapatalk-cdn.com/20180820/82cbb0dbe8821075964ea6aaea5b3483.jpg)
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Really anyone who does not take into account their license plate when "building their bike" is broadcasting the simple signal ... duh ... I didn't think this one through .... what do we do ... what do we do .... OK lets just slap it here ...
Side mount license plates = garbage, side mounts that are turned 90 degrees = garbage ^2 ...
IMHO the largest negative contribution of Idiots of Orange county choppers to the biking world isn't the implication that bikes should cost 250K ... its the acceptability of the side mount license plate by the world at large.
Next week I'll be fitting a side mount license plate ... on my truck. It will be bent and turned on its side and slapped onto the lug nuts. Yea it will be in a $200 billet aluminum fixture complete with vintage limp duck tail light. Yup, onto a lug nut.
Cool.
Buddha.
Im not sure whether that was a pointed or not. Either way...good to know you don't like side mount plates. Neither do it.
Sadly the law has no care for aesthetics, even a showroom ready Ducati Panigale in the UK has a horrendous "parachute out the back" until the owner tidies it up by putting a smaller plate on it. The standard plate here is 9 x 7" which you need to get a MOT every year, that being said you can ride a bike here 99% of the time with a tucked away 8" x 6" plate and never get pulled over, which is what i am going to do. Alot of people ride with smaller.
The coolest no license plate contraption I have ever seen was a laser projected image onto the riders back with a specially designed I think pack that made it visible day or night. When parked, it had no plate, and I wasn't still sure if it was legal or not ... however it was cool as duck. That was in 2005, too bad, it never caught on and instead these retarded contraptions have multiplied like rats.
BTW I am setting an example on my bolt. You should really see what it is ... so I'll post a pic.
Cool.
Buddha.
New paint coming soon !
(https://uploads.tapatalk-cdn.com/20181228/ca092f92cab8242e0fe7201336476eac.jpg)
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(https://www.motohouston.com/forums/images/smilies/headbang.gif)
So I mentioned in a previous post that the digital speedometer converter cable wouldn't fit due to it being too big, 18mm instead of 15mm. I made a simple fix with the end of the original speedo drive, some jbweld and the new cable.
The first picture below shows the size difference.
(https://uploads.tapatalk-cdn.com/20190102/73a6678059ab09c0fc50b3b250c220e3.jpg)(https://uploads.tapatalk-cdn.com/20190102/4be942dd919527a41865428d6cfe05be.jpg)(https://uploads.tapatalk-cdn.com/20190102/b10c0f0b127d9ec1d61663823b79468e.jpg)(https://uploads.tapatalk-cdn.com/20190102/ab828199dece4d728e7437cc2df2de34.jpg)(https://uploads.tapatalk-cdn.com/20190102/687c2684efbdcd3b4cfd2fd0c8f83410.jpg)
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How about some updates, Moto?
I'm planning a rear section round tube mod on my 2004F in the near future.
yea wonder what happ'd with this one :dunno_black:
Tadaa.. just awaiting a respray and polished engine covers.. The 2k paint on the engine covers has debonded from the epoxy primer which I wasn't expecting bad prep on my part no doubt
(https://uploads.tapatalk-cdn.com/20190829/1086c3363fbc7a1a4f6cf8081457fe33.jpg)(https://uploads.tapatalk-cdn.com/20190829/3e1549cd2d4c726737dc168a3c25092a.jpg)(https://uploads.tapatalk-cdn.com/20190829/7071a4c9d538d63c06325456a0c5b9e8.jpg)(https://uploads.tapatalk-cdn.com/20190829/8d25f985965a567f784539210e4272d1.jpg)
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It's running great now, needed another carb rebuild as the needles in the cheap kit I bought before disintegrated. I've also fitted an 8cell battery as I had charging issues, and I think I'm going to get the subframe repowder coated in hi-po silver when I repaint the new colour scheme.
The R6 rear shock is great, but the front end needs some love, does anyone know of a good upgrade kit? I don't really won't to go upside down forks as I don't think the bike needs it.
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I also made some fully adjustable rear sets for the parts bin. They're based on cbr600rr controls
(https://uploads.tapatalk-cdn.com/20190829/bb12d14e1b74ed0fe7c71a6acb0b6fae.jpg)
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I also spaced out the rear sprocket in the end with some custom spacers. Seems to have worked a treat.
(https://uploads.tapatalk-cdn.com/20190829/1433276f38436ed07c0663b73fa1a836.jpg)
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And it's running a keyless ignition as I couldn't find a place for the old ignition switch.
(https://uploads.tapatalk-cdn.com/20190829/50f8aa30b5e900cd55de96691e161e4f.jpg)(https://uploads.tapatalk-cdn.com/20190829/40d4c69ac9c9fd7f4d69764a71d04e4b.jpg)
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I'm also looking for a rear hugger, I wondered if one of these would fit?
Sorry about the bombardment of update posts
(https://uploads.tapatalk-cdn.com/20190829/7229b26fb6e5af867e32cd34f05c0b11.jpg)
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Very cool!!! I like a lot of things about your build :cheers:
I'm not sure if the Bandit 600 hugger could be made to work. The Bandit 400 hugger is the one in the wiki and the one I did the detailed write-up on here:
http://gstwins.com/gsboard/index.php?topic=71283.0
There are also some available online directly for the GS500.
Red Fox:
https://www.red-fox.com/huggers/suzuki-gs500-huggers
Moto Tuning Brasil:
http://www.mototuningbrasil.com.br/Produto/133-Paralama-de-pneu-traseiro-GS-500
The Brasil site is where I bought my belly pan from. I translated my emails to Portuguese so I could communicate with them and they were more than happy to sell and ship to me here in the US.
Edit: I just found this thread. Can't see the pics here at work but it looks interesting!
https://www.bikechatforums.com/viewtopic.php?t=85427&view=next
Thanks showbizwolf, that's good information, my concern is that my rear tyre is larger than stock so my concern is that the "stock" huggers wouldnt fit.
The bandit 600 hugger is built for the same size wheel and tyre so may do the job, I might just have to take a chance and see. 🤞
Or just make my own..... 🤪
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I had it weighed this morning at our local weigh bridge out of intrigue. It's come in at 160kg (352lb?) With a full tank. Based on wiki that's a 24kg saving! Im pretty surprised about that. nearly 14% of added lightness. I cut off and removed alot of crap from the bike but didn't think it would be that much!
That will have added more seat of the pants power to the bike than any power mod I could do bar the new engine that is slowly (read as taking forever) being built.
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This is the current paint scheme proposal, what is everyone thoughts?
(https://uploads.tapatalk-cdn.com/20190830/29806458dcfc73d502a4069c362800f8.jpg)
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Quote from: moto on August 29, 2019, 10:50:50 PM
The bandit 600 hugger is built for the same size wheel and tyre so may do the job, I might just have to take a chance and see. 🤞
Or just make my own..... 🤪
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Servus,
Swingarm Stock : it doesnt fit
Swingarm Bandit : Perfect match
I like the paint as it is. Sweeeet.
That V piece in shifter just made my day. One of my main reasons I don't ride my gs929 much is the reverse shift. I tried a few things and figured I'd have to live with it but with a V piece like you created I could flip it accordingly to get my shifter right. Thanks for that! Kick a@@ build.
That custom spacer is :bowdown: On Seamax's design, on the bandit rear end the chain nips at the lip of the tire. With a spacer like that it'd prob eliminate that. Thanks again for posting this bada@@ery!
Hi CBR if you would like the cad for the spacer I will post it up. I also have a spare going if anyone wants it for a few beer tokens.
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Thanks Jim, is the bandit swing arm a straight fit? I'm assuming I would need to bandit wheel spacers etc?
No doubt the search function will be my friend on this one.
Edit: I just found your very detailed writeup! 🤦🏻♂️
http://www.gs-500.info/index.php?title=Bandit_600_rocker_in_GS
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if a 600 bandit swing arm fits, logic would dictate that a 1200 bandit alloy swing arm would fit as they fit on a 600 bandit.
Enter my current eBay find:
(https://uploads.tapatalk-cdn.com/20190830/cc80064d008085ee80dd9df779e494fa.jpg)
Can i get a 600 /1200 bandit swing arm to work with my katana (gsx750) wheel via the Suzuki parts bin? or am i going to need to make up some custom spacers and brake bar?
Any help would be much appreciated before i start spending money on parts.
This is all such awesome info!! I love it!
I agree about the stock huggers. One of the only reasons my Bandit 400 install is different from the wiki one is because I have a 140/80 rear tire on my GS. It works and looks (IMO) much better than if I had a stock size tire. Not much room for anything bigger though.
Servus,
The Bandit Swingarm fits in the GS . 600 and the 1200.
You need new bushings for the frameaxle.
Sadly due to some major unforseen life circumstances, I'm now going to have to sell my GS500 😢 would anyone on this board be interested? I will post it in the forsale section shortly.
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:cry:
Moto, did you sell the bike?
I see in the other thread that you're rebuilding a GS engine. So I presume you didn't get rid of the bike after all.
I managed to hold on to her! Couldn't let my baby go, so the build continues 😄
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That's great news. I followed this thread and was sad for you when you said you have to sell her. Looking forward to seeing what changes you make to the engine. :thumb:
Great looking build! Not sure how I missed this thread... looks like it was dormant for a while? The proposed red looks great, although I like the solid white as well. My GS café build is "plain old" white but I like to keep things simple. You've done such a nice job on the rest of the build, I'm sure the final paint scheme will look awesome as well. :thumb:
Ditto to all the above! I was eagerly following this build thread 3 years ago.
You've come an amazingly long way Moto! The bike looks amazing.
Not sure if you did anything with the front forks. But getting some stiffer springs (I used Sonic Springs) makes all the difference, and they pair well with the R6 shock.
I considered selling my own GS last year, but with its light weight it's such a great handling bike. I put on some Dunlop Q3's and it's become an awesome machine for racing on the track.
Thanks Guys, don't worry there is more to come!
I don't think I custom bike build is ever really finished is it??
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There is now seats available that has the LED rope taillight already built in.
Cool.
Buddha.