GStwin.com GS500 Message Forum

Main Area => Projects / Builds, Racing and Tech => Topic started by: cbrfxr67 on April 12, 2011, 09:54:10 PM

Title: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on April 12, 2011, 09:54:10 PM
(https://scontent.fhou1-2.fna.fbcdn.net/v/t1.0-9/208146_1988875844835_1210808_n.jpg?oh=735a86e968972738713748da4ad87a47&oe=5A85BBB5)

I picked up my first GS500 last week.  This is the first Suzuki I've had.  The motor had a bad rod bearing and PO decided to dismantle the whole engine.  I'm still deciding whether to get a replacement engine or try and put this one back together.  I'd like to use this post to document my progress and get feedback from the GREAT forum here at GSTWINs.  This forum is really well mannered and informative.  I've been on cbrforum.net and of course customfighters.com for quite awhile now but I'm really enjoying reading the 1200something pages of posts here!  I'm working on posting pictures right now and will continue to do so as the build goes along.  I'm from Houston and here's a 'hello' to all the people at GSTWINs.

(https://scontent.fhou1-2.fna.fbcdn.net/v/t1.0-9/206814_1988876004839_5361967_n.jpg?oh=76c990faa00930771363792d70bb05a1&oe=5A7856D9)
Title: Re: 1996 GS500 Basket Case Build
Post by: cbrfxr67 on April 13, 2011, 12:56:42 AM
So today I test fit an old F2 engine.  I have an F2/3 that I've been learning on for the past few years.  Then I picked up another on the cheap and fixed it also.  With all of the cbr parts I have, I thought I could find another but somehow I ended up with a GS500.  Obviously, I'd try to insert cbr600 engine right?!  For people searching to see if this will work: nope.  Not without modifying the front frame for the exhaust.  The rear wasn't too bad and you could fab some brackets but the exhaust was the dream killer.  (https://scontent.fhou1-2.fna.fbcdn.net/v/t31.0-8/221497_2002527346114_8349588_o.jpg?oh=bfc944be8c5dbabe4f8453b22dae7363&oe=5A481CA9) So, back to my gs500 engine.  PO didn't give me the piston assembly, so I'll have to locate that before I can start putting things back together.
Title: Re: 1996 GS500 Basket Case Build
Post by: cbrfxr67 on April 13, 2011, 01:11:30 AM
Messing around with more F2 parts.  Probably way too big for this bike.  You know how it is when you don't have anything to do without parts and you start going 'hmmmm' and looking around the garage.  (http://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash4/206946_1988877004864_1331504559_2328958_5177647_n.jpg)
Title: Re: 1996 GS500 Basket Case Build
Post by: BaltimoreGS on April 13, 2011, 01:33:55 AM
If I remember correctly, the CBR rear sets will fit if you use a bolt with a smaller head.

-Jessie
Title: Re: 1996 GS500 Basket Case Build
Post by: Twisted on April 13, 2011, 07:59:47 AM
Welcome to the forum CBRFXR. Keep us updated how you go.
Title: Re: 1996 GS500 Basket Case Build
Post by: tb0lt on April 13, 2011, 02:35:33 PM
Is this the red $600 gs that was on Houston CL last week? You bought it from Jake?
Title: Re: 1996 GS500 Basket Case Build
Post by: cbrfxr67 on April 13, 2011, 06:58:28 PM
Yes that's right.  Nice to see fellow Houston rider here!  :)
Title: Re: 1996 GS500 Basket Case Build
Post by: cbrfxr67 on April 15, 2011, 04:10:08 PM
Any opinions on trying to stuff that 600 motor in there?  I'm having a hard time finding a replacement engine that doesn't cost more than the whole bike.  I'm even having a hard time finding a piston/rod assembly to try & rebuild my old one.  Anybody got one lying around?  :dunno_black:
Title: Re: 1996 GS500 Basket Case Build
Post by: tb0lt on April 15, 2011, 04:18:57 PM
Any opinions on trying to stuff that 600 motor in there?  I'm having a hard time finding a replacement engine that doesn't cost more than the whole bike.  I'm even having a hard time finding a piston/rod assembly to try & rebuild my old one.  Anybody got one lying around?  :dunno_black:

I vote for the 600 install into the GS frame. It would be cheaper than a proper rebuild of your old motor. You will end up with a really unique and SUPER fast GS :)
Title: Re: 1996 GS500 Basket Case Build
Post by: BaltimoreGS on April 16, 2011, 12:12:58 PM
As narrow as the GS frame is won't it be hard to get the final drive to line up correctly (assuming stock swing arm)?

-Jessie
Title: Re: 1996 GS500 Basket Case Build
Post by: cbrfxr67 on April 18, 2011, 01:57:53 PM
Most of Saturday I worked on aligning and setting the 600 engine in the frame.  I took a boat load of pictures but jacka** phone isn't cooperating on downloading them.  I'll have to get my digital camera and do it that way.  The mounting points were, of course, way off so I began making jigs to hold the engine while I weld in new tabs.  Basing the position on: making the carbs fit on top and making sure the sprocket/chain line up on rear, I bolted in some hangers.  I'm trying not to cut out/modify the original frame & mounting points as much as possible in case at one point we retro back to the gs engine.  The engine itself fits easily in the space and doesn't touch the frame at all.  The carbs fit, right before the bends in the frame under the tank.  The removable frame piece doesn't want to fit because of the engine mounting tab, which hits the oil pan of the f2 motor.  I'll have to figure out what to do there later.  All in all I was happy that this seems like a doable project.  Pictures to come.  Any suggestions, tips or advice is well appreciated.  :icon_idea:
Title: Re: 1996 GS500 Basket Case Build
Post by: The Buddha on April 18, 2011, 02:05:22 PM
If I were you, I'd fab up an exhaust that will clear the frame, there are people who can do anything with muffler pipe.
Cool.
Buddha.
Title: Re: 1996 GS500 Basket Case Build
Post by: scottychop on April 18, 2011, 03:17:04 PM
Can you make the engine a stressed member of the frame?  Cut the left side to match the right and make two upper mounts. 
Title: Re: 1996 GS500 Basket Case Build
Post by: jeffdodge on April 18, 2011, 04:09:13 PM
I would LOVE to see that. If it can be done, being that the GS frame is just steel, I may have to attempt this down the road.
Title: Re: 1996 GS500 Basket Case Build
Post by: cbrfxr67 on April 19, 2011, 02:16:49 AM
Tonite only had time to mock up one bracket and weld it in.  Still having problems with my pics but I'll get some tomorrow.  Not enough time & energy in the day!
Title: Re: 1996 GS500 Basket Case Build
Post by: the mole on April 19, 2011, 06:11:19 AM
I'm trying not to cut out/modify the original frame & mounting points as much as possible ........ The removable frame piece doesn't want to fit because of the engine mounting tab, which hits the oil pan of the f2 motor.
Cut out the mounting tab, you can always get another removable frame piece if you go back to the GS motor again later.
Title: Re: 1996 GS500 Basket Case Build
Post by: cbrfxr67 on April 19, 2011, 02:59:06 PM
Finally got my phone to cooperate somewhat.  Here's my work space, with the GS, an F3 I reworked, and my cn250 rat. (http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc6/216521_2002483465017_1331504559_2349703_3838845_n.jpg) Another pic of workspace (http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash4/205151_2002500145434_1331504559_2349726_6816561_n.jpg) Of course one of my main concerns was making sure the carbs would fit in the frame and line up correctly. (http://a5.sphotos.ak.fbcdn.net/hphotos-ak-snc6/206509_2002499945429_1331504559_2349725_2887586_n.jpg)(http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash4/208463_2002510585695_1331504559_2349730_6204678_n.jpg) Got carbs? (http://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash4/206669_2002514545794_1331504559_2349731_861129_n.jpg)(http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash4/206654_2002527346114_1331504559_2349748_8349588_n.jpg)That's all I got for now.  Will work on welding more tabs in tonight and try to make some more progress
Title: Re: 1996 GS500 Basket Case Build
Post by: The Buddha on April 19, 2011, 04:20:10 PM
Ooooooo ... engine-swap-gasm. Man that baby fits in there like it was made for it.
Looks like my acheivement of the weekend (fitting a buell blast tank on a GR frame) now is just to be thrown by the side of the road man.
Cool.
Buddha.
Title: Re: 1996 GS500 Basket Case Build
Post by: jeffdodge on April 19, 2011, 05:12:42 PM
Looking amazing. Cant wait to see it done.
Title: Re: 1996 GS500 Basket Case Build
Post by: cbrfxr67 on April 20, 2011, 01:20:15 PM
Ooooooo ... engine-swap-gasm. Man that baby fits in there like it was made for it.
Looks like my acheivement of the weekend (fitting a buell blast tank on a GR frame) now is just to be thrown by the side of the road man.
Cool.
Buddha.
Buddha please honor me with a pic of that buell blast tank you did!  :bowdown:
Title: Re: 1996 GS500 Basket Case Build
Post by: cbrfxr67 on April 21, 2011, 02:17:54 PM
Spent three hours on one bracket last night.  Bottom left behind engine.  I just couldn't get the angle right, or the hole lined up or something or other.  Finally got it tacked in and called it a night.  I'm thinking I'll get them all tacked in good and solid, then drop the engine and weld them in nice without the engine blocking my angles.
Title: Re: 1996 GS500 Basket Case Build
Post by: tb0lt on April 21, 2011, 03:03:04 PM
As long as the engine is supported properly and doesn't put stress on the mounts to distort/move them between the tack and the final weld, that is the way to go.
Title: Re: 1996 GS500 Basket Case Build
Post by: cbrfxr67 on April 24, 2011, 02:45:37 AM
Got my 06 tank in with plenty of dents to fix but I like it better than the old 96 skinny style.  Picked up a rashed 05 600rr tail to fix.  On the lookout for a fe to start messing with too.  Today kept on with getting the mounts welded in.  Had to cut the lower frame removable piece to clear the oil pan.  I lopped off the mounting tab but that wasn't enough, so I had to cut it and reweld it in for more clearance.  Hoping to start the 'exhaust clearance' cut tomorrow as the 4 into one exhaust really needs some time & thought to figure out how to make it work.  Will probably have radiator clearance issues too, so considering a dual radiator set up, one on each side.  Will get some new pics when I finish all the mounts and get some progress to look at.

(https://scontent.fhou1-2.fna.fbcdn.net/v/t1.0-9/229838_2028097065341_3091824_n.jpg?oh=6727d955c96c8e0ec5209ac94e4de074&oe=5A76E072)
Title: Re: 1996 GS500 Basket Case Build
Post by: cbrfxr67 on April 25, 2011, 01:45:36 AM
(http://a5.sphotos.ak.fbcdn.net/hphotos-ak-snc6/223590_2014837213853_1331504559_2370429_3527590_n.jpg)
(http://a8.sphotos.ak.fbcdn.net/hphotos-ak-snc6/222443_2014837453859_1331504559_2370431_4053514_n.jpg)
So much for not cutting the frame too much.  Had to take out a good section on both sides to clear the exhaust.  Will weld back in tomorrow if time & energy allows.  Today, spent a few hours doing the same thing I've been doing. 
Title: Re: 1996 GS500 Basket Case Build
Post by: KlaXon on April 25, 2011, 09:10:23 AM
Dude this will be awesome bike  :bowdown:
Good luck to you. Keep going.
Title: Re: 1996 GS500 Basket Case Build
Post by: Chancegs1996 on April 26, 2011, 09:06:08 PM
Hey dad its me this is going to be a really good bike... Thx for doing it!!!  :2guns: :woohoo: :thumb:
Title: Re: 1996 GS500 Basket Case Build
Post by: Fry on April 27, 2011, 01:52:30 AM
Awesome Build....Love your motivation...Following this thread closely, Great Work.
Title: Re: 1996 GS500 Basket Case Build
Post by: cbrfxr67 on April 27, 2011, 04:22:06 PM
Last night finished welding in the clearance for the exhaust.  Tonite will remove the engine and final weld up the brackets with better angles, having the engine out of the way.  Then I'm thinking I'll either chop off the tail and start on that, or start on the harness.  :icon_question:
Title: Re: 1996 GS500 Basket Case Build
Post by: cbrfxr67 on April 28, 2011, 02:35:48 AM
(http://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc6/225514_2022401482955_1331504559_2384239_2566232_n.jpg)
Tonite dropped the engine and dove into getting my welds right.  I swear that engine must only weighs 80 pounds.  I think half the tub of parts from the gs engine weighs more!  Took me about 15 minutes to get it out of the frame and then I spent the rest of the night welding.  Need more time in the day! Where is the zzzz icon?
Title: Re: 1996 GS500 Basket Case Build
Post by: tb0lt on April 28, 2011, 03:17:26 AM
This is moving pretty fast. Exciting stuff.  :woohoo:
Title: Re: 1996 GS500 Basket Case Build
Post by: jeffdodge on April 28, 2011, 02:36:00 PM
Keep up the good work!  :thumb:
Title: Re: 1996 GS500 Basket Case Build
Post by: cbrfxr67 on April 29, 2011, 02:03:45 PM
Weld, grind, weld, grind, weld, grind,.....if I had more time this would be much more satisfying.  As it is, time blazes by and then I have to call it quits for the evening.  Here you can start to see what I'm going for on the frame mod to clear the exhaust.  I thought it would make things more interesting than just doing a square opening or boring cut.  It's getting there slowly,....(http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc6/221688_2025242993991_1331504559_2387744_6079414_n.jpg)(http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash4/229451_2025243233997_1331504559_2387746_7967127_n.jpg)(http://a5.sphotos.ak.fbcdn.net/hphotos-ak-snc6/224598_2025243434002_1331504559_2387747_5499783_n.jpg)
Title: Re: 1996 GS500 Basket Case Build
Post by: Shepa on April 30, 2011, 06:27:24 AM
Nice project!
(http://www.havenvideo.com/images/smilies/smiley-face-drool.gif)

Have you tried to fit CBR's airbox into the GS frame yet? Any clearance issues?
Later problem as I see it will be mounting the GS gas tank over it all...

I'm asking since I have the opportunity to buy relatively cheap '96. F3, so I'm very much interested in this conversion...  :thumb:
I've already considered puting an Bandit 600 engine (air/oil cooled) into GS, but it's way too big (in all directions).  :icon_mrgreen:

Keep up the good work!
I'm subscribing for this topic.
Title: Re: 1996 GS500 Basket Case Build
Post by: cbrfxr67 on April 30, 2011, 10:12:42 PM
Yes I know the airbox is going to be a challenge.  I'm probably going to get to do something interesting!  :icon_lol:  Today I finally finished the brackets.  So I cut off the tail.  Purists please don't flame me.  Ok sure, tell me what you think.  All opinions welcome.  (http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc6/215291_2028096905337_1331504559_2392296_6082347_n.jpg)(GS taking a nap)(http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc6/226026_2028097505352_1331504559_2392300_8207611_n.jpg)Primed out frame work.  You can see I left the old brackets, except for on the removeable piece.(http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc6/222164_2028097745358_1331504559_2392301_6108090_n.jpg)I know, I know, I just can't stop cutting, grinding and welding.(http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash4/217707_2028097385349_1331504559_2392299_2105453_n.jpg)(http://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc6/224650_2028097225345_1331504559_2392298_1582476_n.jpg)(http://a5.sphotos.ak.fbcdn.net/hphotos-ak-snc6/226924_2028098305372_1331504559_2392304_7426556_n.jpg)(http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc6/227099_2028098545378_1331504559_2392306_8371095_n.jpg)Not sure how I'm going to angle it yet.  I had to quit before I could make up my mind.  I don't want it to look too long.  Give me some feedback and I appreciate yays or nays.  Thanks.
Title: Re: 1996 GS500 Basket Case Build
Post by: 5thAve on May 01, 2011, 12:27:57 AM
I like the lines better when angled like in the 1st pic.

Awesome job you've got going there!  Man, I have to learn myself how to weld. I have an itch to chop something too.
Title: Re: 1996 GS500 Basket Case Build
Post by: jeffdodge on May 01, 2011, 12:37:07 AM
I also agree with that. Lines work better in pic 1.
Title: Re: 1996 GS500 Basket Case Build
Post by: Big Rich on May 01, 2011, 12:41:10 AM
By the title, I thought this was gonna be a run-of-the-mill basket case rebuild. Obviously, I was mislead......

Great work going on here!
Title: Re: 1996 GS500 Basket Case Build
Post by: cbrfxr67 on May 01, 2011, 01:56:50 PM
I might have to change the title,...to quote tb0lt, it's a GS 600 now.   :icon_mrgreen:
Title: Re: 1996 GS500 Basket Case Build
Post by: cbrfxr67 on May 02, 2011, 03:34:51 AM
Today worked on the tail for a couple of hours setting it up and finally welded it on where I think it's right.  Need to go buy tubing and steel tomorrow.-edit I found another 600rr tail but it is different from mine.  I couldn't figure out why my frame covers wouldn't work with my tail but it's obvious now.  I have an 04 tail.  With that, I'll be re-modding the framework to fit this (real) 05-06 tail which go with my frame covers.
Title: Re: 1996 GS500 Basket Case Build
Post by: jeffdodge on May 02, 2011, 04:30:37 PM
 :cheers:

watching...
Title: Re: 1996 GS500 Basket Case Build
Post by: cbrfxr67 on May 04, 2011, 03:00:49 AM
(http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc6/225336_2035546371569_1331504559_2403368_6439921_n.jpg)Nothing special today.  Got somemore supplies but ran out of time before I could make a lot of headway.  I'm thinking of cutting the lower tail braces off at the main frame and then sticking some vertical red leds right there.  Respect to Seamax for inspiration on this build btw.  God Bless America.
Title: Re: 1996 GS500 Basket Case Build
Post by: Shepa on May 07, 2011, 09:17:40 PM
Any progress?
Title: Re: 1996 GS500 Basket Case Build
Post by: cbrfxr67 on May 08, 2011, 01:37:07 AM
Been working and reworking the tail section.  I didn't think it was going to be as complicated as it is.  I could've just slapped something up there but I want to ride two up and have to reinforce it to be able to carry weight.  So through the week I've been trying to figure out how to go about this.  I copied Seamax's design early on with the lower supports and then I built my way back to the end of the tail.   tb0lt gave me a proper tip to keep the tail from being too long and I've been readjusting, eyeballing, adjusting all week long.  Pain in the shaZam!  Well made progress today and took a couple of pictures.  The plastic for the 04 is too wide at the bottom towards the tank and the plastics for the 06 are too short and the frame covers don't line up well with the tank.  I think I'll go with the 04 and take a 2" section out of the middle to make it fit better.  Tomorrow, plan on doing more reinforcing, grinding, checking my welds, and finishing the subframe if possible.
(http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc6/225887_2043786377564_1331504559_2414526_2422496_n.jpg)(http://a8.sphotos.ak.fbcdn.net/hphotos-ak-snc6/229789_2043786177559_1331504559_2414525_5372609_n.jpg)
Title: Re: 1996 GS500 Basket Case Build
Post by: 4strings on May 08, 2011, 02:40:00 AM
Definitely watching (http://i13.photobucket.com/albums/a255/ahuacate/Smilies/eatpopcorn.gif)
Title: Re: 1996 GS500 Basket Case Build
Post by: cbrfxr67 on May 09, 2011, 12:09:32 AM
Today worked on the tail more.  Welded in more boxing and support and finally jumped up and down on it for the final test.  Squeezing the tail to fit of course makes it bow so I went to town with a burr to alleviate the stress.  I didn't want to start bodywork this early, but luckily I'm handy with the plastic welder.  haha.  I need a seat, maybe a rear cowl or rear seat to figure out where to weld in my seat brackets.  I think I will get a later year gs500 seat and cut it to fit.  I want it to look right on the tank.  I didn't get as much done today as I wanted, being Mother's day and all, but at least I managed a few hours.
(http://a8.sphotos.ak.fbcdn.net/hphotos-ak-snc6/228435_2046004393013_1331504559_2418476_3950824_n.jpg)
Title: Re: 1996 GS500 Basket Case Build
Post by: cbrfxr67 on May 10, 2011, 01:09:42 AM
Kind of a lowsy depressing day today.  Didn't feel like doing much after work so did some 'busy' work degreasing & scrubbing.  My oil pan is cracked on my 600 motor & I got one in that was in need of some cleaning.  That was it for today.  blah
(http://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash4/226416_2048547616592_1331504559_2423414_1935521_n.jpg)
Title: Re: 1996 GS500 Basket Case Build
Post by: gregvhen on May 10, 2011, 03:41:17 AM
Does the countershaft sprocket line up with the rear sprocket? Sorry if you addressed this before I only skimmed the first few pages
Title: Re: 1996 GS500 Basket Case Build
Post by: cbrfxr67 on May 10, 2011, 01:57:39 PM
The carbs and the alignment of the sprockets were my first two main concerns after deciding I could pull off the exhaust clearance.  Checked, rechecked and checked again and felt everything was ok to proceed.  I read the forums everyday, I think I'm on page 501 today and I've seen over and over where guys said you couldn't use an inline 4 because the sprockets wouldn't line up, but I think it'll be good.
Title: Re: 1996 GS500 Basket Case Build
Post by: cbrfxr67 on May 10, 2011, 05:36:58 PM
Got a new lid today.  It is an AFX-39 ds.  I wanted something a little different and decided to try this one.  Inside is really comfy, shield is clear with no distortion.  I wanted a visor for the afternoon Houston (inferno) sun.  I'll have to update later to tell how it works and what the wind is like on it.  It has good venting and I like it.  Kind of looks like Master Chief from Halo though.  haha  What do you guys think?
(http://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash4/230753_2049976212306_1331504559_2425266_7634050_n.jpg)
(http://a8.sphotos.ak.fbcdn.net/hphotos-ak-snc6/224728_2049976692318_1331504559_2425267_4737552_n.jpg)
Title: Re: 1996 GS500 Basket Case Build
Post by: The Buddha on May 10, 2011, 05:47:39 PM
I might have to change the title,...to quote tb0lt, it's a GS 600 now.   :icon_mrgreen:

GS600RR to be precise.
Cool.
Buddha.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: The Buddha on May 10, 2011, 05:49:38 PM
Changed the topic. If you dont like it, let me know what you would like.
Cool.
Buddha.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: cbrfxr67 on May 11, 2011, 01:53:52 AM
Tonite cleaned up my engine some & then remade one of the engine mounts, cut up some plugs to fill in the holes in rear subframe & the two where the lower subframe connected.  Didn't get to weld tonight but looking forward to plugging those holes tomorrow evening.  Then I'll put the engine back in and start figuring out wiring and where electrical components, etc need to be mounted, oh and the battery.  Picked up a cheap 600rr seat before I could get a later GS seat.  Need to find a rear seat or cowl to get my seat brackets welded in. 
And thanks Buddha.  I'm on page 500 twenty something and still haven't come across one single (non-gs) engine swap with pictures.  Didn't you do one already?  Where is that link?  Yes, I searched for it and got nothing,....?
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: werase643 on May 11, 2011, 05:05:29 PM
it is/was a gs/gr650.... probably sitting in his garage covered in 1/2 inch of dust

my DR-GS650 probably has 1/8 inch of dust on it
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: The Buddha on May 11, 2011, 05:51:43 PM
Yea that GR swap is now looking like a huge waste of time ... cos GSXR's and CBR's that have been crunched are a dime a dozen. Seriously when you fininsh this, we're gonna see a flood of GSXR and CBR and ZX and R6 and what not swaps. One fool already has a R6 motor in a chopper ... so the GS is next I wanna say.
Cool.
Buddha.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: kml.krk on May 11, 2011, 06:25:41 PM
awesome build. keep up the great work and pace!
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: Shepa on May 11, 2011, 07:16:47 PM
Yea that GR swap is now looking like a huge waste of time ... cos GSXR's and CBR's that have been crunched are a dime a dozen. Seriously when you fininsh this, we're gonna see a flood of GSXR and CBR and ZX and R6 and what not swaps. One fool already has a R6 motor in a chopper ... so the GS is next I wanna say.
Cool.
Buddha.
You said it bro.
This sunday I'm off to check out a '96 F3 with 25k km's on it.
Hopefuly, the project starts by the end of the month.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: The Buddha on May 11, 2011, 08:09:26 PM
Get the RR motor, its FI and smaller ... the F3 motors were huge.
Cool.
Buddha.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: werase643 on May 11, 2011, 08:23:55 PM
you should finish it.... or bring it to me and pay me slave labor to finish it (X per hr times whatever it takes)  then you can polish the rest of it
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: The Buddha on May 11, 2011, 08:37:23 PM
you should finish it.... or bring it to me and pay me slave labor to finish it (X per hr times whatever it takes)  then you can polish the rest of it


I might just do that ... but its shelved till next year likely. Maybe this winter ...
I actually will bring you something better ... How about a GR/Buell Blast Basterd ... yea ... then we slap on a kat FE and a DR swingarm and ...
Oh wait ... no truck ... crammed full of crap and electrical shutdown ... grrrr, K winter ...
Cool.
Buddha.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: cbrfxr67 on May 11, 2011, 08:40:54 PM
"Looks like my achievement of the weekend (fitting a buell blast tank on a GR frame) now is just to be thrown by the side of the road man." -Buddha
I'm still waiting for that pic!
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: werase643 on May 11, 2011, 09:00:45 PM
I think i have less $$$ in my F3 than any one GS
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: The Buddha on May 11, 2011, 09:01:59 PM
He he ... its not an acheivement of skill ... more like an acheivement of memory ... I saw the buell blast tank once ... and 3 years later I saw the GR frame and figured it will fit like a glove ... and it does.
Pics ... yea some time, its crammed in the front of the truck with a bunch of other crap behind it.
Cool.
Buddha.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: cbrfxr67 on May 12, 2011, 02:09:06 AM
Tonite welded in the plugs and ground them down.  Sorry no pics, but I'll get some tomorrow.  Something Shepa mentioned was the airbox and I started looking under the tank, real easy with no engine in the way, and there certainly is a small space there.  Beginning to think about what to do since there is only a small pie slice of space.  First idea is to use the lower airbox piece and then mold in a new top for it under the tank, maybe with a couple of cone filters.  Should be fun trying to figure out this part of the puzzle.  I really don't want to cut into the tank to make room for the airbox.  Also looking for a front end.  No offense but I loathe those stock handlebars on the gs.  I can pick up an F1 or F2 front end set up pretty cheap, but not sure if I'm ready to start messing with that yet.  Wish I had more time in the day.  Tonite we actually got some rain, it was peaceful and serene throughout the neighborhood, oh except for me grinding welds under the carport, sparks flying everywhere!  haha
(http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc6/230832_2055154501760_1331504559_2431190_6142033_n.jpg)Before,...
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: tt_four on May 12, 2011, 04:10:15 PM
Project looks great! I just found it for the first time last night.

Have you looked into using individual filters instead of a whole airbox? You might be able to work that out easier than a whole airbox although I know space is still tight on the outside 2 carbs.

A front end swap would definitely look better on the bike with the new gas tank and tail. A good USD front end would look best! I ended up swapping my old tank for one of the new ones, they look much better. You thought about trying to fit a bandit rear wheel so you can get a wider rear tire to match the new tail?? Looking forward to watching the rest of your build!
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: cbrfxr67 on May 12, 2011, 04:37:16 PM
I'm not sure how to incorporate the pod filters.  I know they do it on the sprint cars that use these engines but I've never seen the way they are adapted to the carb.  I should look into that.  And definitely will do a rear swingarm swap eventually.  These tires are in like new shape, but when they get worn out I want to do the swingarm swap.  I already have an F3 swingarm but I believe it is too wide to fit (9").  Also, I'm sure I will do the front end change to get rid of those awful gs handlebars.  Need more time in the day!
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: DoD#i on May 12, 2011, 11:50:12 PM
Looking good.

When you get there, if you happen to want a 525 sprocket that fits a GS wheel, the better to match what you probably have for a drive sprocket on the cbr motor, I still have 2 for sale.

http://gstwins.com/gsboard/index.php?topic=50359.0
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: cbrfxr67 on May 13, 2011, 02:22:06 PM
Thanks for the offer DoD#i.  I'm going to go with a 14t 520 on the front and probably a 40 on the rear.  I have a 50t but I think that will be too much!
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: seamax on May 13, 2011, 02:54:50 PM
(http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc6/230832_2055154501760_1331504559_2431190_6142033_n.jpg)Before,...

COOL! FYI if you are looking for the an LED bar to fit these holes I got my brake/running/turn signal led bars from Targa Accessories but they have change their website format and I can't find them on there anymore but such sites as this have them...

http://www.chromeglow.com/store.asp?pid=12590
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: Twism86 on May 13, 2011, 03:02:29 PM
Awesome work, keep the updates coming. I always wondered at what point cant you call it a GS anymore?
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: cbrfxr67 on May 13, 2011, 04:04:33 PM
Thanks Seamax.  That's exactly what I was going to do, with all (much!) respect to your (amazing!) build.  Got my 600rr seat in today.  It's funny how getting the seat will spur you to really want to speed things up so you can try it out!
(http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc6/227789_2056508415607_1331504559_2432432_6850619_n.jpg)
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: jeffdodge on May 13, 2011, 04:41:57 PM
Well, get to work then! lol. On a more serious note, its  come quite a way and its looking like its getting there. i cant wait to see video of this thing.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: cbrfxr67 on May 15, 2011, 04:10:03 AM
Did somemore today.  First tried smoothing out the grand canyon sized holes in the frame from where the lower supports were.  Still some work to do there, but okay for now.  Next went into getting the seat set up and figuring out where to mount the pieces so the seat would sit right and have enough support.  Used my handy unibit to cut holes in the tail faring for later, where I can get the tank off without taking the whole tail off.  I'll put some nice plugs in these holes so they won't be noticeable.
(http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash4/227340_2060899925392_1331504559_2437287_5279333_n.jpg)
Here's where I was trying to get the seat to sit correctly.  even though it looks like the tail is really long over the tire, it is the angle of the picture.  I'll try to take a pic straight on so the tire vs tip of the tail is clear.  Also the two louvered panels are what I am going to make an undertail with.  With some red leds or something behind the louvres.  They came off a battery charger that went in the trash.  I'm bad about taking pieces off of junk.  You never know when you might use something.
(http://a5.sphotos.ak.fbcdn.net/hphotos-ak-snc6/225415_2060899765388_1331504559_2437286_8202381_n.jpg)  
And here's where I quit for the day.  The seat still needs the front mounts aligned and set.  Still have to move the tail around to get it lined up right and I may have to make some small triangular pieces to fit along the seat and frame if there is a space left.  Hope to get more done tomorrow.
(http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc6/229178_2060900045395_1331504559_2437288_7295180_n.jpg)
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: tt_four on May 15, 2011, 04:25:36 AM
Looking sweet man!
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: cbrfxr67 on May 15, 2011, 09:26:09 PM
(http://a5.sphotos.ak.fbcdn.net/hphotos-ak-snc6/228432_2063213943241_1331504559_2439518_7446017_n.jpg)
Worked on getting the seat finished today.  Sitting position really feels great, well for not going anywhere it does.  The cover rippled up because of the angle.  I'll likely recover it in a heavier material.  I was surprised at how cheap the vinyl is from the stock seat of a 600rr.  Cleaned up the subframe and then primered it.  I still have the rear seat to do, but I don't have one yet.  Got an integrated tail light coming from Hong Kong.  I'm kind of undecided what to do next.  I need to clean up my old engine more and then stuff it back in there and get to the wiring.  I want to build the undertail because I have the idea in my head.  I want to do a front end swap.  Also, need to start fixing that tank; was considering trying to weld in a bung to use the cbr petcock, since I have 4 or 5 lying around.  I've never welded on a tank though, not sure I wouldn't mess it up.  
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: Pelikan on May 15, 2011, 10:50:30 PM
This is so awesome.   :cheers:
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: cbrfxr67 on May 20, 2011, 03:56:29 PM
Not much progress this week.  Been caught up in schedules and stuff.  Looking to get on it this weekend, get the engine back in the frame, cleaned up and prepped.  I figure if I get that done I'll be happy.  Got a rear seat cowl coming from hong kong too.  I'll be glad when I can get the back end finished where I don't ever have to take it off again. ha 
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: The Buddha on May 20, 2011, 05:31:19 PM
The 600RR tail IMHO is a bit fat assed for the tank and tire ... pics from straight behind or straight in front or from top - like riders view standing next to it show that quite obviously. So are most sport bikes for a GS IMHO, I've dreamt of the sv ... but well ...
Cool.
Buddha.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: cbrfxr67 on May 21, 2011, 10:42:14 PM
(http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc6/250614_2079440948906_1331504559_2456386_5509859_n.jpg)
(http://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc6/227316_2079441108910_1331504559_2456388_1272873_n.jpg)
(http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash4/250748_2079441028908_1331504559_2456387_5527765_n.jpg)
(http://a5.sphotos.ak.fbcdn.net/hphotos-ak-snc6/247310_2079440828903_1331504559_2456385_4131829_n.jpg)
(http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash4/248512_2079441388917_1331504559_2456390_4225383_n.jpg)
(http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash4/248711_2079441308915_1331504559_2456389_6098353_n.jpg)
Skipped cleaning up the engine and just stuffed it back in there, cleaned up all my grinding dust etc off the frame instead.  Most of my time today was finding bolts that fit well and the washers/lock washers to go with them.  The first time around I just grabbed whatever I had that would work.  Tossed the tail, tank & seat on to take a few pictures of how it looks with the engine in it.  Didn't get to the exhaust or any wiring.  Tomorrow looking to do more.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: Shepa on May 22, 2011, 07:16:15 PM
Great work man... keep it coming!!!

I'm about to buy that bike I was examining last weekend. Actually, it turns out to be F2 not F3, which IMHO is even better, because the simpler the better.
No throttle sensors/secondary air/solenoid valves and other mumbo jumbo...
I'm only concerned about the airbox and radiator clearance... but...
I'll hang 'em down the sides if there's no other way...  :icon_mrgreen: :icon_mrgreen: :icon_mrgreen:
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: SecretAgent on May 22, 2011, 11:11:54 PM
This is really coming together..Good Work!
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: cbrfxr67 on May 23, 2011, 03:10:07 AM
I agree Shepa on the F2 vs the F3.  F2 is simpler without the F3 'extras.'  Today I spent all day working on the airbox.  I figure go for the hard stuff first.  haha  I mocked it up and got the dimensions and basic plan.  I am big on 'using what you got' and all I could find was the front of an old Snap On toolbox for metal.  Measure, cut, bend, flip, bend, hammer, weld,...I did this all day and still didn't finish.  There isn't much room at the top of the carb.  Down from there, it only opens up to maybe three inches in a pie shape.  I have to save room for my battery, someplace.  I don't want to relocate it up the tail.  The top piece in the picture mounts to another 'plate' that attached to the carbs themselves.
(http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash4/225517_2082053734224_1331504559_2460682_5208274_n.jpg)
(http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc6/250237_2082053934229_1331504559_2460684_2259847_n.jpg)
I'm still not sure how to do this.  Today may have been just a beginning exercise in figuring out what to do.  If I choose to use this first idea, I'll have to mount a pod filter under it, or a flat style filter on top.  Going to take some time to solve this puzzle.  Anyone got ideas?   :icon_question:
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: jeffdodge on May 23, 2011, 01:52:00 PM
No ideas from me.... but wow. doing a killer job.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: cbrfxr67 on May 26, 2011, 01:16:47 AM
So, scrapped the first idea using the light steel version.  Tried to clean up the airbox and make it work and couldn't get it to cooperate so onto the next thing.  Thicker metal?  Fiberglass?  Aluminium?  Plexiglass?  Abs?  A Cornwell dealer and avid rider that I know told me to use fiberglass.  Said it was easy and I couldn't really mess it up because you just keep going till you get it right.  I've never fiberglassed before but why not?
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: jebz240 on May 26, 2011, 02:03:18 AM
why not cold air?
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: jeffdodge on May 26, 2011, 04:47:53 AM
Fiberglass is pretty easy to do... Though I dont know how I would go about it in this configuration
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: Shepa on May 26, 2011, 11:16:07 AM
My idea is to use the lower piece of cbr airbox (the one that's bolted to carbs), stuff some filtering material (sponge perhaps) in it, and make a plastic lid/cover for it, either made from original airbox (de/formed with hot air fan), or custom made from fiberglass (shouldn't be too difficult).

Right now, everything is just pure theory and pictures/service manuals/cbr forums checking and rechecking, can't wait to get hold of the donor bike to finally start the project.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: cbrfxr67 on May 26, 2011, 04:44:40 PM
I think I will go with the fiberglass idea first.  I already have the mat and the resin/hardener isn't much $.  Maybe the 'lost foam' process will work:  make the mold, cover it in wax paper, fiberglass it up, then spray acetone inside to dissolve the foam.  I think this would work depending on the strength of the final piece.  It isn't going to be a stressed part and I can make a bracket to support it when mounted.  Time to go get some foam & resin,...
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: cbrfxr67 on May 29, 2011, 04:02:34 AM
(http://a5.sphotos.ak.fbcdn.net/hphotos-ak-snc6/255728_2097902890443_1331504559_2480355_6901350_n.jpg)
Today started trying to fiberglass the airbox.  Set up a mold out of wood and gave it a shot.  Thought I'd wait a couple of hours and wanted to clean up the headers.  My old vise stand was an old watercooler which never worked from the beginning but I was too lazy to do something about it.  My header kept tipping over till I got annoyed and fab'd up a little stand.  My work level is typically me sitting on old cat litter buckets so this little stand sits at the same level.  Needless to say, I ran out of time and didn't even crack my mold open.  I did test out an old chain, just to be sure I had clearance on the swingarm.  I was pretty happy to see that all was good.  This is a 530 so the 520 will be even better.(sorry for the dark pic, should've turn on the lights)
(http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash4/252238_2097902690438_1331504559_2480354_6017072_n.jpg)
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: hhlragnarok on May 29, 2011, 08:05:32 AM
so how can u fit the carb into GS frame?
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: cbrfxr67 on May 29, 2011, 11:53:48 PM
It isn't the carb that won't fit.  It is the airbox that needs a mod to be able to make it work.  The carb fits (see pic) but there is no room between it and the gs tank.  That is my puzzle that I am working to solve right now.
And, didn't get a chance to do anything after Saturday.  Hopefully today when I pop the 'mold' open it will be a good.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: hhlragnarok on May 30, 2011, 06:23:43 AM
It isn't the carb that won't fit.  It is the airbox that needs a mod to be able to make it work.  The carb fits (see pic) but there is no room between it and the gs tank.  That is my puzzle that I am working to solve right now.

How about just cut the bottom of the stock tank and re-weld it?
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: kml.krk on May 31, 2011, 03:33:39 PM
If you happen to do any welding on the gas tank just be careful.
I was told that even if it's empty it can still explode due to fumes gathered inside  :dunno_white:
Theoretically tank should be filled with water before you do any welding on it.
I have no idea whether it's true. I am not a welder. Good case for Mythbusters I guess  ;)

Anyways it never hurts to be preventive!
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: Twism86 on May 31, 2011, 04:44:57 PM
If you happen to do any welding on the gas tank just be careful.
I was told that even if it's empty it can still explode due to fumes gathered inside  :dunno_white:
Theoretically tank should be filled with water before you do any welding on it.
I have no idea whether it's true. I am not a welder. Good case for Mythbusters I guess  ;)

Anyways it never hurts to be preventive!
The best bet is to purge it with a non-flammable gas. Nitrogen for example, if you dont have that some dry ice would probably work.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: Big Rich on June 01, 2011, 08:10:12 AM
Theoretically tank should be filled with water before you do any welding on it.


No offense kml.krk, but that is absolutely not true. You don't want water any where near something getting welded. After all, we are talking about enough electricity to melt steel.

I've seen everything from blow dryers, heat guns, and car exhausts used to dry out a tank before welding. Or fancy shmansy nitrogen........
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: kml.krk on June 01, 2011, 04:27:47 PM
^^^
that's a good point.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: cbrfxr67 on June 02, 2011, 01:46:51 AM
No updates yet.  Did get my tail light in which really looks nice.  Working on pulling engine, transmission, wiring (everything) out of my van to do a swap into my older van.  This will take me a few days before I can get back to the GS.   :technical:
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: hhlragnarok on June 02, 2011, 03:06:35 AM
No updates yet.  Did get my tail light in which really looks nice.  Working on pulling engine, transmission, wiring (everything) out of my van to do a swap into my older van.  This will take me a few days before I can get back to the GS.   :technical:

can't wait to see ur progress man.....
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: Shepa on June 02, 2011, 11:43:38 AM
In the meantime, here are couple of my pics...

Comparing the sizes...  :icon_mrgreen:

(http://img855.imageshack.us/img855/867/dsc01005sd.th.jpg) (http://img855.imageshack.us/i/dsc01005sd.jpg/)

And (some of) the work in progress...

(http://img10.imageshack.us/img10/7642/dsc01015vl.th.jpg) (http://img10.imageshack.us/i/dsc01015vl.jpg/)...(http://img824.imageshack.us/img824/2479/dsc01010j.th.jpg) (http://imageshack.us/photo/my-images/824/dsc01010j.jpg/)
(http://img850.imageshack.us/img850/4749/dsc01019a.th.jpg) (http://imageshack.us/photo/my-images/850/dsc01019a.jpg/)...(http://img802.imageshack.us/img802/4355/dsc01021t.th.jpg) (http://imageshack.us/photo/my-images/802/dsc01021t.jpg/)...(http://img542.imageshack.us/img542/8344/dsc01020v.th.jpg) (http://imageshack.us/photo/my-images/542/dsc01020v.jpg/)
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: cbrfxr67 on June 02, 2011, 02:34:37 PM
Wow Shepa!  Looking really good!  scottychop told me to use the engine as a stressed member and I didn't listen, wanting to keep the gs's frame relatively the same.  I think I should've done it your way.  Looks much easier and less weight is always better.  Also you were able to mount it lower than I did without the frame in the way which will give you more room on top.  I can't wait to see how you do the airbox!  You're really making great progress!!  Please keep posting pictures!  Awesome!
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: The Buddha on June 02, 2011, 03:06:56 PM
How is the motor standing there ?
BTW I think cbrfxr67's is a better looking one atleast as of now. The front frame rails give it the needed triangulation, cos steel bends, aluminum is super stiff and the aluminum frames are built with no welds in the neck - you dont get a weld in an aluminum frame till you get ti the widest point of the frame, I'm thinking the front frame rails would help with flex. There also needs to be a good place to hang a radiator.
Cool.
Buddha.

In the meantime, here are couple of my pics...

Comparing the sizes...  :icon_mrgreen:

(http://img855.imageshack.us/img855/867/dsc01005sd.th.jpg) (http://img855.imageshack.us/i/dsc01005sd.jpg/)

And (some of) the work in progress...

(http://img10.imageshack.us/img10/7642/dsc01015vl.th.jpg) (http://img10.imageshack.us/i/dsc01015vl.jpg/)...(http://img824.imageshack.us/img824/2479/dsc01010j.th.jpg) (http://imageshack.us/photo/my-images/824/dsc01010j.jpg/)
(http://img850.imageshack.us/img850/4749/dsc01019a.th.jpg) (http://imageshack.us/photo/my-images/850/dsc01019a.jpg/)...(http://img802.imageshack.us/img802/4355/dsc01021t.th.jpg) (http://imageshack.us/photo/my-images/802/dsc01021t.jpg/)...(http://img542.imageshack.us/img542/8344/dsc01020v.th.jpg) (http://imageshack.us/photo/my-images/542/dsc01020v.jpg/)
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: Shepa on June 02, 2011, 10:05:32 PM
2 Buddha: Yes, yes, and yes, of course.  :thumb:

This was only the provisional mounting, for measuring and placement checking purposes.
The GS frame is significantly lighter/softer than CBR's, so I suppose it wouldn't be the smartest idea to leave it like that.
I've tried pushing the bike down, and I felt it stretching a bit, imagine what it would do when riding, so the front frame is a must.
The engine is going to be fixed at all the mounts possible, and the front frame will be made from thicker pieces of tubing (GS's tubing is like a bad joke, when you cut it and actually see what you're riding).
I have a CBR radiator minus the fan, so I've found one taken off of some Italian scooter, hopefully it'll do for now.
I even considered buying a Hornet 600 radiator (because the CBR's is like 19" LCD size) but they cost a fortune.

2 cbrfxr67: Thanks man! Wish I could say I did all the work myself, but the truth is, I have a very talented friend with years and years of experience in field of machining, welding and all kinds of engineering. I usually come up (on a weekly basis) with a thing or two (I always have some fresh mod ideas about my bike :icon_mrgreen:), and he just looks at me like "you really ARE insane", but in the end he enhances the ideas and modifications with his own vision.
No wonder his nickname is "Tesla".

Right...
As for the airbox issue, the idea (Tesla's  :icon_mrgreen:) is to actually use the GS airbox in it's original position, and construct the 4 plastic (or rubber) intake funnels for each of the carbs.
What can I say, the man's a genius. Sometimes the simplest solutions work the best. My idea was to use the bottom part of the CBR's airbox, stuff it with some filtering material and make some kind of lid with intake openings, but you must agree his even better (that way we'll use the proper air filter).

Here are a few pics from today's work:

(http://img594.imageshack.us/img594/4844/dsc01027l.th.jpg) (http://imageshack.us/photo/my-images/594/dsc01027l.jpg/)...(http://img703.imageshack.us/img703/4421/dsc01023kg.th.jpg) (http://imageshack.us/photo/my-images/703/dsc01023kg.jpg/)...(http://img545.imageshack.us/img545/7449/dsc01022t.th.jpg) (http://imageshack.us/photo/my-images/545/dsc01022t.jpg/)...(http://img51.imageshack.us/img51/8959/dsc01030i.th.jpg) (http://imageshack.us/photo/my-images/51/dsc01030i.jpg/)...(http://img163.imageshack.us/img163/2339/dsc01029h.th.jpg) (http://imageshack.us/photo/my-images/163/dsc01029h.jpg/)...(http://img27.imageshack.us/img27/3846/dsc01028gi.th.jpg) (http://imageshack.us/photo/my-images/27/dsc01028gi.jpg/)...

Tomorrow the engine's getting out of the frame, everything is going to be welded properly and then repainted. That should be the end of the easy part.
After that, the real stuff begins.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: werase643 on June 03, 2011, 02:10:04 AM
I have a spare custom made AL radiator for a 99-03 SV650
increased cooling 40% over stock
made for endurance racing several years ago
brand new never used
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: cbrfxr67 on June 03, 2011, 01:56:21 PM
Fantastic work Shepa!  I really like how you made the lower frame rail bend out, clear the exhaust and meet up with the mount on the engine.  Very Nice.  I also like the idea of using the GS' airbox.  I can't wait to see what set up you come up with.  I'm not sure if I'm more excited about seeing your progress or getting more done on mine!! (?!!)
Got in my new 14t cbr front sprocket & 39t rear GS sprocket & my chain plus got my rear cowl which also makes me want to finish up the tail and sew up the undertail as well.  I'm stuck working on my engine/transmission swap this weekend, but maybe I can spare a couple hours for the GS!
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: Shepa on June 04, 2011, 08:05:00 PM
Busy saturday...
(http://img31.imageshack.us/img31/3402/dsc01044q.th.jpg) (http://imageshack.us/photo/my-images/31/dsc01044q.jpg/)

A bit of welding...
(http://img69.imageshack.us/img69/4417/dsc01036m.th.jpg) (http://imageshack.us/photo/my-images/69/dsc01036m.jpg/)

A bit of grinding...
(http://img853.imageshack.us/img853/1354/dsc01040e.th.jpg) (http://imageshack.us/photo/my-images/853/dsc01040e.jpg/)

(http://img121.imageshack.us/img121/1656/dsc01039oa.th.jpg) (http://imageshack.us/photo/my-images/121/dsc01039oa.jpg/)...(http://img20.imageshack.us/img20/5785/dsc01046nv.th.jpg) (http://imageshack.us/photo/my-images/20/dsc01046nv.jpg/)...(http://img38.imageshack.us/img38/5413/dsc01048ue.th.jpg) (http://imageshack.us/photo/my-images/38/dsc01048ue.jpg/)...(http://img851.imageshack.us/img851/2302/dsc01045v.th.jpg) (http://imageshack.us/photo/my-images/851/dsc01045v.jpg/)...

The artist himself... Tesla!
(http://img7.imageshack.us/img7/7854/dsc01031fy.th.jpg) (http://imageshack.us/photo/my-images/7/dsc01031fy.jpg/)

"Man I'm exhausted..."
(http://img194.imageshack.us/img194/7295/dsc01050n.th.jpg) (http://imageshack.us/photo/my-images/194/dsc01050n.jpg/)

OK, let's call it a day, but not before baby's goodnite bath.
(http://img217.imageshack.us/img217/9193/dsc01057mb.th.jpg) (http://imageshack.us/photo/my-images/217/dsc01057mb.jpg/)
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: ben2go on June 05, 2011, 08:32:33 PM
Shepa.Nice build.Where are you located?What country?
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: cbrfxr67 on June 06, 2011, 04:12:28 PM
(http://img194.imageshack.us/img194/7295/dsc01050n.jpg) Those rails are pure art Shepa.  I'm really liking those lines.  Can't wait to see more.  :bowdown:
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: Shepa on June 06, 2011, 08:02:56 PM
Those rails are pure art Shepa.  I'm really liking those lines.  Can't wait to see more.  :bowdown:
Thanks man! Today nothing special, just prep for tomorrow's painting.

(http://img839.imageshack.us/img839/1275/dsc01059d.th.jpg) (http://imageshack.us/photo/my-images/839/dsc01059d.jpg/)...(http://img860.imageshack.us/img860/8365/dsc01060x.th.jpg) (http://imageshack.us/photo/my-images/860/dsc01060x.jpg/)

Yeah... I know, those front mounts are different, but that's just for now (don't ask).  :icon_mrgreen:
The original design had a flaw: the engine would be (almost) impossible to unmount, hahaha.

Anyway, how's your project going? Can't wait to see what you're up to next. That RR end is awesome (although a tiny bit agressive on a naked bike, but that's just me). Love your work.
Any progress on airbox? Man, that's gonna be tight, today I thought of something else (stainless steel tubes on a piece of stainless plate bolted to carbs, and then rubber hoses to airbox), but it turns out there's no space under the tank. It's gonna be fiberglass afterall. There's just no other way.

So... post more pictures, dude! Afterall you gave me an idea for a project. I thought of Bandit or Katana engines but they were just too bulky so I just gave up... Then I saw your idea, and that was it...
I would never thought of CBR's engine, so I must thank you again! And what an engine it is... a reliable power plant in such a compact size.
Since there are no geometry changes, I'm pretty sure it will be rideable, only thing that concernes me is a possible front end wobble (happened before), I'll have to find a propper forks, or at least steering damper.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: ben2go on June 06, 2011, 10:58:43 PM
Bringing the front up or the rear down will help eliminate the head shake.I can't recall right off what the GS rake is from the factory.35 to 37 degrees maybe?
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: The Buddha on June 07, 2011, 02:56:07 AM
I thought it was closer to 25 ... a savage is about 33, GS has to be 25 or less.
Cool.
Buddha.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: Shepa on June 07, 2011, 06:55:08 AM
Bringing the front up or the rear down will help eliminate the head shake.I can't recall right off what the GS rake is from the factory.35 to 37 degrees maybe?
You're right. Come to think of it... I've installed a SV rear shock without cutting/drilling the new mount hole, so the back end of the bike is higher (approx 4-5 cm) than factory settings. I suppose it changed the rake for about a degree or two. I'll try to correct it with CBR's rear shock (shorter and more adjustable than SV's).  :thumb:
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: cbrfxr67 on June 07, 2011, 09:10:47 PM
Shepa: going to work fairings onto the bike eventually.  I want to go with the GS F front and the cbr tail.  But, woe, right now I'm stuck in swap limbo on my van.  Poor GS is surrounded by parts from my donor van.  Not enough time & energy in the day for everything I want/have to do!!
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: Shepa on June 07, 2011, 09:40:48 PM
Shepa: going to work fairings onto the bike eventually.  I want to go with the GS F front and the cbr tail
Sweeeeeeeeeeeettt!!! Can't wait to see it finished!

Not enough time & energy in the day for everything I want/have to do!!
I know... there's just no hours enough in a day (after a full time job)... especially when the primer starts to peel off... grrr...

(http://img29.imageshack.us/img29/4134/dsc01061i.th.jpg) (http://imageshack.us/photo/my-images/29/dsc01061i.jpg/)...(http://img835.imageshack.us/img835/8584/dsc01062c.th.jpg) (http://imageshack.us/photo/my-images/835/dsc01062c.jpg/)

Well... at least the swingarm looks like new.
Hopefully, the engine will be mounted till the end of this week.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: ben2go on June 07, 2011, 10:23:42 PM
I thought it was closer to 25 ... a savage is about 33, GS has to be 25 or less.
Cool.
Buddha.

Suzuki service manual says 35 degrees.I checked with the stealership service department.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: Shepa on June 09, 2011, 09:28:31 PM
Just a little teaser...

(http://img64.imageshack.us/img64/743/dsc01064y.th.jpg) (http://imageshack.us/photo/my-images/64/dsc01064y.jpg/)...(http://img839.imageshack.us/img839/5823/dsc01063qj.th.jpg) (http://imageshack.us/photo/my-images/839/dsc01063qj.jpg/)...(http://img834.imageshack.us/img834/6518/dsc01065nz.th.jpg) (http://imageshack.us/photo/my-images/834/dsc01065nz.jpg/)...(http://img822.imageshack.us/img822/5232/dsc01068b.th.jpg) (http://imageshack.us/photo/my-images/822/dsc01068b.jpg/)...(http://img88.imageshack.us/img88/9240/dsc01069h.th.jpg) (http://imageshack.us/photo/my-images/88/dsc01069h.jpg/)

The only thing fixed is the engine.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: cbrfxr67 on June 10, 2011, 02:04:04 PM
So the plate across the carbs bends up and the two cut outs feed air from the box?  Looking good, I have questions boiling, but I'm just going to be quiet and watch cause I know they'll get answered here shortly.  Love how it is coming together!  :woohoo:
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: kml.krk on June 10, 2011, 02:56:17 PM
I have a question too  :D
Will you be able to legally register it and ride?

If you plan to keep current registration, then what about yearly inspection? Do you think you can pass it?

By the way, your skills are awesome and bike looks gorgeous! Keep up the great work!
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: cbrfxr67 on June 10, 2011, 06:20:44 PM
I'd take it to 'Cycle Sports Ltd of Houston' & get it inspected.  As long as everything works, I'm sure it'd be good.  My F2/3 doesn't quite look like a cbr anymore (according to the traffic cop that stopped me yesterday just to ask me what it was :dunno_black:) but it passed inspection easily.  Registration here is easy with clear paperwork on the frame.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: kml.krk on June 10, 2011, 08:10:56 PM
yeah but judging by electrical outlet in Shepa's garage he is located somewhere in Europe, unless he's got retrofitted 220V outlet for his welder.
If he is in Europe inspection requirements may be different.

It seems logical though that if everything works you should be able to legally ride a modified vehicle providing you have paperwork for parts.

Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: ben2go on June 10, 2011, 08:21:36 PM
yeah but judging by electrical outlet in Shepa's garage he is located somewhere in Europe, unless he's got retrofitted 220V outlet for his welder.
If he is in Europe inspection requirements may be different.

It seems logical though that if everything works you should be able to legally ride a modified vehicle providing you have paperwork for parts.



He is some where across the pond.I ask where in an earlier post but he isn't given up the location of Shepa Skunk Works.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: Shepa on June 11, 2011, 05:40:47 AM
yeah but judging by electrical outlet in Shepa's garage he is located somewhere in Europe, unless he's got retrofitted 220V outlet for his welder.
If he is in Europe inspection requirements may be different.

It seems logical though that if everything works you should be able to legally ride a modified vehicle providing you have paperwork for parts.



He is some where across the pond.I ask where in an earlier post but he isn't given up the location of Shepa Skunk Works.
:icon_mrgreen: :icon_mrgreen: :icon_mrgreen: :icon_mrgreen: :icon_mrgreen:
Sorry, I didn't bother to reveal the big secret, since it's written in my profile.
And yes... Croatia is in Europe.  :D
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: ben2go on June 11, 2011, 01:48:35 PM
yeah but judging by electrical outlet in Shepa's garage he is located somewhere in Europe, unless he's got retrofitted 220V outlet for his welder.
If he is in Europe inspection requirements may be different.

It seems logical though that if everything works you should be able to legally ride a modified vehicle providing you have paperwork for parts.



He is some where across the pond.I ask where in an earlier post but he isn't given up the location of Shepa Skunk Works.
:icon_mrgreen: :icon_mrgreen: :icon_mrgreen: :icon_mrgreen: :icon_mrgreen:
Sorry, I didn't bother to reveal the big secret, since it's written in my profile.
And yes... Croatia is in Europe.  :D

Nice.I hear that your area is a nice place to visit.I hope to visit Europe when I retire.I'm semi retired at the moment.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: tesla on June 12, 2011, 08:08:32 PM
You have to see Croatia....
http://www.google.hr/search?q=photos+croatia&hl=hr&sa=X&biw=1024&bih=570&prmd=ivns&tbm=isch&tbo=u&source=univ&ei=oxz1Tf3yLIXRsgbyu8WdBg&ved=0CCMQsAQ


Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: ben2go on June 12, 2011, 11:38:48 PM
You have to see Croatia....
http://www.google.hr/search?q=photos+croatia&hl=hr&sa=X&biw=1024&bih=570&prmd=ivns&tbm=isch&tbo=u&source=univ&ei=oxz1Tf3yLIXRsgbyu8WdBg&ved=0CCMQsAQ





 :thumb: Looks like a great first stop.  :thumb:
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: Shepa on June 13, 2011, 01:08:01 PM
Well... nothing much over the weekend... except the first starting of the engine inside GS frame...  :icon_mrgreen:

I must say... the thing sounds MEAN, like it wants to rip someone's leg off... I think I'll rename the bike to "Pure Evil".
It even wants to jump off the kickstand when revved, although there's no chain on sprockets yet...  :o
We had some carb issues, but everything's solved.

And yeah... as you can see, the Tesla man is on-board, although he's not much of a talker... he's a worker!!!
And what a work it is...

 :thumb: :thumb: :thumb:

Btw, today some eBay stuff (http://cgi.ebay.com/ebaymotors/Gauges-Speedometer-Honda-CB400-CB-400-92-93-94-km-h-_W0QQcmdZViewItemQQhashZitem1c1a2731c1QQitemZ120697860545QQptZMotorcyclesQ5fPartsQ5fAccessories) arrived.  :woohoo:


Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: Twism86 on June 13, 2011, 02:29:46 PM
Nice work both of you guys. I cant wait to see how they turn out.

Nice signature cbrfxr67  :icon_lol:
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: The Buddha on June 13, 2011, 03:09:30 PM
The engine is going to be fixed at all the mounts possible, and the front frame will be made from thicker pieces of tubing (GS's tubing is like a bad joke, when you cut it and actually see what you're riding).

Oh I've cut it plenty ... the big cruisers too awfully thin paper thin literally, the GS tank and exhaust pipe is thicker than the frame almost.
Cool.
Buddha.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: crzydood17 on June 13, 2011, 05:33:10 PM
is your next upgrade going to be a full carbon fiber frame to support such insanity? I request videos of running bike!
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: cbrfxr67 on June 13, 2011, 05:54:55 PM
Everytime I climb over my mountain of van parts I longingly look at the waiting GS.  So far got engine, trans, dash, wiring harness (any1 ever pulled a wiring harness out of a van-shaZam!), subframe, fenders, tank, miscellaneous crap, off and am going for the rear axle, then glass, doors odds n ends next.  Getting closer to getting back on the GS project, day by day.
Shepa:  what'd you get? >> "Btw, today some eBay stuff arrived"   What kind of issues did you have with carbs?  Please elaborate?  For me, the most pita part has always been carbs.  Syncing them was #1 problem eliminator after cleaning them over and over (and over x15).
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: Shepa on June 13, 2011, 10:05:02 PM
Everytime I climb over my mountain of van parts I longingly look at the waiting GS.  So far got engine, trans, dash, wiring harness (any1 ever pulled a wiring harness out of a van-shaZam!), subframe, fenders, tank, miscellaneous crap, off and am going for the rear axle, then glass, doors odds n ends next.  Getting closer to getting back on the GS project, day by day.
Shepa:  what'd you get? >> "Btw, today some eBay stuff arrived"   What kind of issues did you have with carbs?  Please elaborate?  For me, the most pita part has always been carbs.  Syncing them was #1 problem eliminator after cleaning them over and over (and over x15).
Sorry, I guess the eBay link didn't work, I ordered some (Chinese) replicas of CB400 SuperFour speedo/tach gauges, and they seem pretty close to the real thing.
I'll have to wait to test 'em on the road to tell the difference.  :icon_mrgreen:

(http://img155.imageshack.us/img155/8519/dsc01079sm.th.jpg) (http://imageshack.us/photo/my-images/155/dsc01079sm.jpg/)

Anyway... the wiring is slowly getting in it's place, and the GS airbox needs a slight modification to make room for wires and coolant bottle.
(http://img846.imageshack.us/img846/9972/dsc01076a.th.jpg) (http://imageshack.us/photo/my-images/846/dsc01076a.jpg/)...(http://img717.imageshack.us/img717/4149/dsc01080si.th.jpg) (http://imageshack.us/photo/my-images/717/dsc01080si.jpg/)...(http://img34.imageshack.us/img34/76/dsc01081r.th.jpg) (http://imageshack.us/photo/my-images/34/dsc01081r.jpg/)

About the carbs... well one of 'em is flooding occasionally, couldn't pinpoint the exact reason, everything seems in order, the needles, the floaters, jets... everything's cleaned and functional, with no signs of wear.
Perhaps the engine needs a little bit of riding till everything sits in it's right place. Afterall, it's been sitting in PO's shed for the last 5 or 6 years.

It's gonna be ok when I attach the hose to the petcock, so the vacuum won't let it flood, but I'm not quite happy knowing it's not 100% as I want it to be.

is your next upgrade going to be a full carbon fiber frame to support such insanity? I request videos of running bike!
:icon_mrgreen: :icon_mrgreen: :icon_mrgreen:
Hahahaha, I hope it won't be needed, but thanks for the idea.  :thumb:

Anyway... the other day a friend came to Tesla's garage, stood there puzzled for a minute or so, and then asked me why am I doing it, why bother when I could sell my (perfectly running) GS, add a money I've spent on 17 years old CBR and buy myself "a proper bike" like... Hornet or something... (Btw, he has a 2006 CBR1000RR Repsol Edition).
I said... "where's the fun in that"?

And besides... if I live to tell, imagine owning a one of the only two such bikes in the World... one in Europe (mine), the other one in The States (cbrfxr67's).  :icon_mrgreen:
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: werase643 on June 13, 2011, 11:32:43 PM
where does the radiator fit in this picture
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: xunedeinx on June 14, 2011, 03:15:06 AM
I want one. :bowdown:
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: Shepa on June 14, 2011, 06:44:12 AM
where does the radiator fit in this picture
The usuall place, only it's not mounted yet.  :thumb:
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: cbrfxr67 on June 14, 2011, 03:48:33 PM
"where's the fun in that"?  :cheers:  Exactly!!!!
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: tesla on June 15, 2011, 10:38:38 AM
He he he
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: reload on June 15, 2011, 02:44:58 PM
“There are those who look at things the way they are, and ask why... I dream of things that never were, and ask why not?” Robert Francis Kennedy

just keep on keepin on  :cheers:
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: Shepa on June 16, 2011, 12:01:15 AM
There... radiator in it's place.

(http://img845.imageshack.us/img845/9083/dsc01083y.th.jpg) (http://imageshack.us/photo/my-images/845/dsc01083y.jpg/)...(http://img34.imageshack.us/img34/7726/dsc01086at.th.jpg) (http://imageshack.us/photo/my-images/34/dsc01086at.jpg/)...(http://img194.imageshack.us/img194/3884/dsc01084kt.th.jpg) (http://imageshack.us/photo/my-images/194/dsc01084kt.jpg/)...(http://img215.imageshack.us/img215/7740/dsc01085ym.th.jpg) (http://imageshack.us/photo/my-images/215/dsc01085ym.jpg/)

There are no clearance issues, not with fender, nor with forks, and even the fan isn't touching anything.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: ben2go on June 16, 2011, 03:10:13 AM
A hard bump may send the fender up into the radiator.I'd strap it down real good and then check the clearance between the fender and radiator.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: crzydood17 on June 16, 2011, 04:47:47 AM
everyones style is there own... but imho the radiator looks a little meh... ever thought of doing a fairing?
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: Shepa on June 16, 2011, 05:29:36 AM
A hard bump may send the fender up into the radiator.I'd strap it down real good and then check the clearance between the fender and radiator.
True, but the springs have enough preload not to (35mm longer spacers). We'll see after the first test ride.


everyones style is there own... but imho the radiator looks a little meh... ever thought of doing a fairing?
Nah... I'm really not into faired bikes, I've always been a fan of naked ones. If there's no engine visible... it just looks like a plastic toy to me.

It does look a bit Frankensteinish, but I believe the gas tank over it will change the perspective.
And if it doesn't... well... I'll just have to get used to it.  :dunno_black:
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: crzydood17 on June 16, 2011, 05:56:06 AM
chrome the radiator perhaps? or color match the endcaps to the rest of the bike? might make it blend in more and not be so boooing
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: Shepa on June 16, 2011, 07:10:03 AM
chrome the radiator perhaps? or color match the endcaps to the rest of the bike? might make it blend in more and not be so boooing
Yes, I thought about chrome grill or something...

Something like this (maybe too much):
(http://img11.rivercrane.jp/catalogue/11832/520-y110s.jpg)

or like this (minimalistic detail):
(http://www.abart-group.com/images/product_images/info_images/7654.jpg)
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: cbrfxr67 on June 16, 2011, 02:26:35 PM
I guess I'm already used to it.  Looks A Ok to me!  :star:
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: Shepa on June 17, 2011, 08:07:06 AM
First test ride yesterday...

 :icon_mrgreen: :icon_mrgreen: :icon_mrgreen:
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: cbrfxr67 on June 17, 2011, 02:23:49 PM
THAT'S IT????!  What a teaser that was!  How was it????  :technical:
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: xunedeinx on June 17, 2011, 09:00:36 PM
I think i speak for everyone on here...

Video, please? :bowdown:
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: Shepa on June 17, 2011, 10:18:35 PM
Sorry... no videos just yet.
I was so much enjoying it, I forgot to hand my cell-phone to anyone to film the ride.
Just got this last light picture after the ride.

(http://img143.imageshack.us/img143/2862/dsc01088s.th.jpg) (http://imageshack.us/photo/my-images/143/dsc01088s.jpg/)

First impressions...
There's no comparison to GS. It should feel familiar since it's basically the same bike... but it doesn't.
First thing I've noticed is the lack of engine braking I was so accustomed on GS.
Second... I'll have to adjust the footpegs (cbr's), they're too high so there's more bodyweight on the front (I felt my forearms pumping a bit), even with raisers.
As a result, the steering appears a bit... slow, but it's too early to tell, since I hadn't test it on the open road (and the footpegs thing).
The power... the torque... well... pretty much the same.  :icon_mrgreen: (at about 1/8 of the throttle opened, that is).  ;)

And today my heart almost broke when the cam chain tensioner finally passed away...
Yesterday it was (slightly) rattling just for a minute upon turning the bike on (till the oil pressure builds up), but today... it just died I suppose.
A couple of panic phone calls... but no luck, no-one had the spare, so...
Tesla drilled the original one's housing, and converted the damn thing to manually adjusted type!  :woohoo:

(http://img594.imageshack.us/img594/9162/dsc01092hh.th.jpg) (http://imageshack.us/photo/my-images/594/dsc01092hh.jpg/)

OMG... what a sweet... sweet sound this engine has, with no cam chain rattling... music to my ears...
Ahhh yes... one more thing... compared to GS's... this gearbox is so soft, I hardly noticed the gear changes...



Well... that's it for today.

We got plenty of work to do yet, adapt the pegs, mount the headlight, figure out the wiring for the new gauges, wrap everything up so it's not flying around the forks, find some piece of pipe for muffler mounting... and test the bike properly.

Hopefully, there'll be some videos... X-rated ofcourse, cuz the new ride is... orgasmic.  :D
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: ben2go on June 18, 2011, 12:27:35 AM
I agree about the GS gear box.It is a little clunky compared to some other bikes.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: Shepa on June 18, 2011, 05:54:58 AM
Just one more (very) interesting thing I must share...

Since the output shaft is now "higher" than swingarm's pivot point, the drive chain actually extends (not tightens) when you sit on the bike.
Therefore, when unloaded (extended suspension), the chain has to be tensioned to it's full length in order to have some slack when you sit on the bike.
At first, I thought there's a possibility of too loose chain when two onboard, but it seems fine. I'll need to test it on bumpy road to make sure.

I suppose it'd be perfect if all three points (output shaft, swingarm pivot point and rearwheel shaft) were in-lined, but... who cares, I can't wait to go for a ride!

Finally there's no way to overtight the chain.  :icon_mrgreen: With my homemade automatic chain oiler, it should last... well even longer.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: ben2go on June 18, 2011, 05:44:31 PM
Just one more (very) interesting thing I must share...

Since the output shaft is now "higher" than swingarm's pivot point, the drive chain actually extends (not tightens) when you sit on the bike.
Therefore, when unloaded (extended suspension), the chain has to be tensioned to it's full length in order to have some slack when you sit on the bike.
At first, I thought there's a possibility of too loose chain when two onboard, but it seems fine. I'll need to test it on bumpy road to make sure.

I suppose it'd be perfect if all three points (output shaft, swingarm pivot point and rearwheel shaft) were in-lined, but... who cares, I can't wait to go for a ride!

Finally there's no way to overtight the chain.  :icon_mrgreen: With my homemade automatic chain oiler, it should last... well even longer.


What about using a spring loaded idler sprocket to keep down chain whip?
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: Shepa on June 18, 2011, 09:30:16 PM
What about using a spring loaded idler sprocket to keep down chain whip?
I don't think it'll be needed, for now it seems ok.

This morning I took it for a ride (without headlight and mirrors) to an exhaust workshop to make a piece of curved pipe for muffler mounting.
I enjoyed every second of the ride, even without the rear brake (yesterday I forgot to top up breaking fluid after bleeding).
The bike is too much fun to ride. The only downside is I'll need a new rear tire pretty soon, cuz the bike loooooves powerdrifting.  :icon_mrgreen:

This evening we finally wired the gauges (still need to make a new mounting points for them)... sorry, I was so exhausted I completely forgot to take any pictures.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: Chancegs1996 on June 19, 2011, 01:56:42 AM
How fast do u think this bike is gonna be cbrfxr67? What would be the top speed? Ive looked it up but every review ive found says different things...  :dunno_black:
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: crzydood17 on June 19, 2011, 11:18:45 AM
i would be very careful with full throttle and top speed... that is triple if not more the stock power... running through small tires and a weak frame...
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: ben2go on June 19, 2011, 04:45:00 PM
i would be very careful with full throttle and top speed... that is triple if not more the stock power... running through small tires and a weak frame...

GS frame isn't weak.I have two that have been flipped at high speed.One was over the front of a car.Both are still square and usable.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: Shepa on June 20, 2011, 10:10:30 AM
i would be very careful with full throttle and top speed... that is triple if not more the stock power... running through small tires and a weak frame...
Well... since it's a non-faired bike, I don't think there'll be problem with top speed stability.
Given the wind pressure to my chest and helmet, I'd never reach the top speed anyway.  :icon_mrgreen: :icon_mrgreen: :icon_mrgreen:
Btw, the front frame is now made of thicker material than original, and the engine is holding everything tightly together.

I'm running a 150/55 R17 rear tyre on Kat/Bandit wheel, maybe even install the 160, and for the front, I maybe swap the complete front end with Hornet's or Gixxer's, but that mod is yet to come... when I could afford it.
Right now, I'm planing to replace front callipers with some of 4 or 6-piston type (that Repsol Honda friend said he'll give them for free), just to improve the stopping power.

As of a complete package... I now consider the bike a naked cruiser with overtaking ability upgraded.
The gearing is 15 front (JT 520 conversion), 39 rear (standard GS), so the launch off the line is not so brutal as someone would think, but rather linear and strong, steady pull.
It would be if revving up to red line (13k) before every gear change, but it's somehow sweeter to ride in the midranges than to hear it scream...
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: cbrfxr67 on June 20, 2011, 01:27:35 PM
 :bowdown: Fantastic stuff Shepa!  What else are you going to do to it before you call it 'done?'
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: The Buddha on June 20, 2011, 01:51:55 PM
I agree about the GS gear box.It is a little clunky compared to some other bikes.

Man I would say yes to this one, but one thing I'll give the GS is ... the feel is immaculate. The thign also has the same throw from gear to gear and shifts very much that same exact way gear to gear and also year to year ... also one gear to another is also about the same distance in terms of rpm ... a good medium ratio transmission all the way across.
The MZ I am working/riding ... 1-2 is a huge jump in terms of rpm. Rev the thign till it turns blue in 1st and shift to 2nd and you'd be lugging the motor. Then 3-4 and 5 are very close.
Then there is the throw, 1-2 is a huge arc of the lever (making that lugging part worse cos it takes longer to shift) and 2-3 is shorter, and 4 and 5 and literally touch it and its there. WTF, these east germans are nuts. Oh wait a sec, its a yamaha ...  :cookoo: I'll agree though singles are the hardest to design transmissions for though.

Cool.
Buddha.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: xunedeinx on June 20, 2011, 09:22:19 PM
:bowdown: Fantastic stuff Shepa!  What else are you going to do to it before you call it 'done?'

Make a video, perhaps? :bowdown:
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: Shepa on June 21, 2011, 07:30:49 AM
Sorry guys, couple of minor issues left to take care of, so no videos just yet.

That exhaust pipe I got welded the other day has the wrong angle, so my boot heel is hitting the can, and the rear brake cannot be adjusted any lower (and it's a bit uncomfortably high at the moment) without hitting the pipe.

Second thing... I'll have to take a GPS measuring of the speedo deviation (I guess the precision is proportional to the price).

This morning I took the GS stock air filter out, since it somewhat choked the engine at higher speeds.
I guess I'll (or more likely Tesla :icon_mrgreen:) have to figure out some kind of higher flow filter. K&N costs a fortune I'm not willing to pay.

The problem as I see it is in lower capacity airbox, and lower volume of that carburettor intake box, but that was the only way to put everything under the GS gas tank.

What else...
The headlight beam has to be adjusted... and that's about it, I guess.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: xunedeinx on June 21, 2011, 01:05:34 PM
There's a lot of round automotive filters like the stock filter that are larger, but may be able to be made fit by making the opening bigger..

Was considering it at one point, but decided the stocker is good enough until I decide to go buddha jets and lunchbox.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: GAS on June 21, 2011, 01:47:17 PM


Second thing... I'll have to take a GPS measuring of the speedo deviation (I guess the precision is proportional to the price).


You're using that CB400 speedometer, right? Remember that not every bike uses the same ratio between wheel speed and cable speed.  Maybe CB400 is too different from GS500 mechanism. If this is the case you have two solutions:

1- Swap the wheel gear for a CB400 one (I don't believe it will fit)
2- Check the error with a GPS and make a new scale to that speedometer, open it and swap the scale.

Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: Shepa on June 21, 2011, 02:23:22 PM
...
2- Check the error with a GPS and make a new scale to that speedometer, open it and swap the scale.
I thought of something like this.  :thumb:
If deviation is linear, I'll just take the needle off, and put it a couple km/h's +/-, till the reading is accurate.
If it's not linear, I'll either set it to some middle point deviation and live with it, or install the GS speedo into CB400's housing...

There's a solution to every problem, one way or the other.  :icon_mrgreen:
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: xunedeinx on June 21, 2011, 02:25:29 PM
Who needs a speedo.  8)
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: Big Rich on June 24, 2011, 09:32:45 AM
I've heard that all Metric speedometers use the same ratio- but I only work on older bikes so they may have changed it. The 2 easiest options if they aren't the same: 1) make a new speedo overlay out of vinyl with the speed matching the needle or 2) go with an aftermarket digital unit. They can be programmed to any wheel diameter.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: cbrfxr67 on June 27, 2011, 02:50:15 PM
Where are you at Shepa?  Update?  Video?  Finished pictures??  :bstar: :bstar: :bstar: :bstar:
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: Shepa on June 27, 2011, 11:37:14 PM
Where are you at Shepa?  Update?  Video?  Finished pictures??  :bstar: :bstar: :bstar: :bstar:
I refuse to post any other updates till you post yours!  :icon_mrgreen:

Just kidding... in fact I'm enjoying the bike so much, I don't have the time to take a single photo of it, I'm just topping the tank and keeping on riding.
Tomorrow I'll try, I promise.  :thumb:

This weekend I took it for a cca 400-500 km ride with some fellas (one TDM 900, two Fazers 600 S2, and one MT-01), and it was pretty much ok, except the wind gusts (strong NW wind called "Bura") so my neck still hurts. I checked the gas mileage and it's 5,4 l/100km, which is not so bad, considering the thirsty cavalry under the tank and not so touristic riding tempo.

OK, here are couple o' pics...

(http://img20.imageshack.us/img20/8657/dsc01093f.th.jpg) (http://imageshack.us/photo/my-images/20/dsc01093f.jpg/)
A bit of offset needed to avoid pain in the knees and numbness in lower legs (it's still adjustable though).

(http://img62.imageshack.us/img62/3426/dsc01098c.th.jpg) (http://imageshack.us/photo/my-images/62/dsc01098c.jpg/)
Custom/handmade hi-flow air filter...  :icon_mrgreen:
Although... the volume of GS airbox is too low compared to cbr's, so we'll need to drill a couple of additional holes for better air suction.
What can I do... there's just no space enough underneath the gas tank.

(http://img802.imageshack.us/img802/304/dsc01100cu.th.jpg) (http://imageshack.us/photo/my-images/802/dsc01100cu.jpg/)
And here's my beauty, waiting for my working day to finish.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: FJCharlie on July 02, 2011, 04:46:53 PM
Shepo ODLICHAN POSAO! Svaka chast ljudino! (great work shepo! well done man!)  :thumb:
i was foloving your progress and was thinking of your air problem all the time, since 600rr needs a loads of air to run... i see youve come to a solution, but is it enough? i thought of ram-air solution but you would be weakening allready weak frame for that engine...
anyways, congrats on this one!  :thumb:
ill be in Split around 24th-25th of july so if youre free we could meet, a beer, two...  would love to see that beauty run :)

Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: Shepa on July 02, 2011, 07:02:31 PM
For now... the engine gets all the air it needs, revs evenly to 13k in every gear without hesitation.
Well... I didn't get to 13k in sixth because of the slight front end wobble when I passed 200 km/h (GPS measurement).
Maybe I could've push it all the way, but didn't want to take any chances (yet).
Don't know what the top speed is, but it gets to 200 in no time, which is more than enough for every day commuting.  :icon_mrgreen:
The wobble may also occur because of the top case, or my bar weights are too light... dunno.
It's controlable, but over 200 km/h the front end feels like it's in the air, and the steering gets too light.
In any case, I might opt for a steering dumper if necessary.


As for your visit to my hometown... Sure thing man, just pm me when you get here!  :thumb:

Who knows, I may even persuade you to buy that spare GS engine (or CBR leftovers) I now have.  :icon_mrgreen: :icon_mrgreen: :icon_mrgreen:
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: cbrfxr67 on July 05, 2011, 02:18:09 PM
Great Work!  Loving those pictures!  As for me, I got my van stripped and gone, let my other two bikes go, and now have a lot of elbow room to get back on the GS.  Partytime!  :icon_mrgreen:
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: The Buddha on July 05, 2011, 05:45:48 PM
Holee cow shepa, you certainly make us look like lazy idiots.
Cool.
Buddha.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: cbrfxr67 on July 05, 2011, 08:13:14 PM
How tall are you Shepa?  Wondering about what you did on the offset on the rearsets to avoid pain.  Were your knees 'too' bent?  Looks good though.  I need to install mine as well.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: Shepa on July 05, 2011, 10:11:55 PM
Great Work!  Loving those pictures!  As for me, I got my van stripped and gone, let my other two bikes go, and now have a lot of elbow room to get back on the GS.  Partytime!  :icon_mrgreen:
Can't wait to see your project finished, dude.
If I can help in any way (via photos or anything), just ask.
The project is proven to work (yeah I know, no videos yet), so get it on already!  :icon_mrgreen:

How tall are you Shepa?  Wondering about what you did on the offset on the rearsets to avoid pain.  Were your knees 'too' bent?  Looks good though.  I need to install mine as well.
I'm 182 cms tall, and sitting with cbr footpegs fitted to GS peg frame holes was quite crumped, so we made a steel plate which allowed to move cbr's peg backwards and lowered it a bit (it's visible on that photo, the peg simply "rotates" around the lower mounting hole in frame, and is fixed in desired position).
I don't know, I prefer more upright sitting position, but the bike's geometry just forces me to lean forward (even with bar raisers).
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: djkdjk07 on July 06, 2011, 07:20:23 AM
This thread got majorly derailed. I want to see more of the GS600
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: lucky4034 on July 06, 2011, 10:11:07 PM
^Here Here

I wish there was a subforum dedicated to just "projects" ...  there are some great restorations and modifications going on in this place
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: cbrfxr67 on July 07, 2011, 02:47:15 AM
This is a great forum lucky4034!  Better than cbrforum.net, motohouston.com, customfighters.com and any other one I've ever been a part of!  Welcome by the way.  Personally, I like the open forum so that everybody can dig in and comment and help out.  I'd as much like Pandy's opinion, as Buddha's on whether my airbox idea is going to work or not.   :icon_mrgreen:
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: pookiebear on July 07, 2011, 03:57:49 AM
airbox. I made one one time with radiator hose attached to the carb. a piece of PVC in the hose with a pod filter on the pvc. Worked good enough.
Your idea might work but it might not work well. Only way to know is to try it.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: xunedeinx on July 07, 2011, 05:38:27 AM
How much free time do you have to prefect the air filter?

Heres a long drawn out hair-brained idea that'd work great, but take some time to do..

Go to a pick and pull, get an airbox from a car..

Chop off the section that holds the panal filter, so its basically a frame with the latches holding the filter.

Place it in front of the rear shock, directly behind the carbs..

now, mock up with cardboard a box to fit in the space, going to the filter...

And, finally, fiberglass that SOB!

Custom air filter, that free flowing (it is made for a 2000cc or so car), and has replacement filters for 5 bucks at walmart...

Whats not to love?

-Justin
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: lucky4034 on July 07, 2011, 01:14:13 PM
This is a great forum lucky4034!  Better than cbrforum.net, motohouston.com, customfighters.com and any other one I've ever been a part of!  Welcome by the way.  Personally, I like the open forum so that everybody can dig in and comment and help out.  I'd as much like Pandy's opinion, as Buddha's on whether my airbox idea is going to work or not.   :icon_mrgreen:

Thank you, glad to be part of the clan.  (my first bike)  I've been lurking for a couple of weeks and this place is awesome!  Definitely a ton of good information to soak up (though most of it is well over my head at this point)...  keep up the good work :thumb: 

Both bikes look great and its impressive to see "the capable" do their thing!
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: Shepa on July 08, 2011, 09:41:41 PM
This thread got majorly derailed. I want to see more of the GS600
OK...  :icon_mrgreen:

(http://img15.imageshack.us/img15/5703/dsc01105fq.th.jpg) (http://imageshack.us/photo/my-images/15/dsc01105fq.jpg/)...(http://img12.imageshack.us/img12/1362/dsc01104lc.th.jpg) (http://imageshack.us/photo/my-images/12/dsc01104lc.jpg/)...(http://img811.imageshack.us/img811/1575/dsc01109k.th.jpg) (http://imageshack.us/photo/my-images/811/dsc01109k.jpg/)...(http://img854.imageshack.us/img854/2947/dsc01106s.th.jpg) (http://imageshack.us/photo/my-images/854/dsc01106s.jpg/)...
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: The Buddha on July 08, 2011, 09:58:19 PM
This is a great forum lucky4034!  Better than cbrforum.net, motohouston.com, customfighters.com and any other one I've ever been a part of!  Welcome by the way.  Personally, I like the open forum so that everybody can dig in and comment and help out.  I'd as much like Pandy's opinion, as Buddha's on whether my airbox idea is going to work or not.   :icon_mrgreen:

True and thanks, and man, you've stomped on anything I have ever done in terms of the enormity of this you and shepa are in a league of your own.
This forum I can tell you is better for any bike that I have owned than that bike's dedicated forum especially in terms of rolling knowledge, as in if I had a savage I'd get info by searching the savage forum, that I call static knowledge. However post a question in the savage forum and you get nothing. You post a savage question on this forum and you will get a lot of sensible answers.
Cool.
Buddha.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: Chancegs1996 on July 09, 2011, 07:16:06 PM
Come on shepa!!! We need a video!!!  >:(  :cookoo:
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: squirrel-22 on July 10, 2011, 04:01:27 AM
To bad you cann't some how hide that big motor behind a GS faring.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: lucky4034 on July 10, 2011, 04:27:24 AM
Wouldn't that be like buying your wife a boob job and then forcing her to wear turtlenecks?
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: xunedeinx on July 10, 2011, 11:08:48 AM
Wouldn't that be like buying your wife a boob job and then forcing her to wear turtlenecks?

Its what we call a "sleeper"! :thumb:
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: xunedeinx on July 13, 2011, 10:23:59 AM
Oh man, this is SO Project section material!!!

Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: Fry on July 13, 2011, 12:06:37 PM
Holee cow shepa, you certainly make us look like lazy idiots.
Cool.
Buddha.

I've followed this whole post and thats exactly what I kept thinking, in the time it took me to figure out and place my Petcock and a few wiring and electronic items on my Street Fighter project, this Hurricane stuffed a CBR engine into a GS and made it look damn nice, Does anyone have any High Grade Coke so I can up my output levels....

Nice work man, truley nice work.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: Twism86 on July 13, 2011, 02:03:32 PM
Shepa, what luggage do you have on there? I NEED that! Does it come off easy?
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: cbrfxr67 on July 13, 2011, 02:04:48 PM
Can I get moved to the project section?
 
And all the noteworthiness is to Shepa on this build since he smoked my a** in finishing it first.  Ok, much respect to Tesla, but still.:bowdown:  And as soon as I get my bars in from xunedeinx  I'm going to get back on track.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: Shepa on July 13, 2011, 02:29:55 PM
Shepa, what luggage do you have on there? I NEED that! Does it come off easy?
The top case?
It's a Givi, although I forgot the exact model (some old 30-ish liter model).
It comes off the mount (Givi Monorack for GS500) in a second, just turn the key and press the lower button (the upper is for case opening).

http://www.givi.it/index-en.php (http://www.givi.it/index-en.php)
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: Twism86 on July 13, 2011, 02:39:58 PM
Shepa, what luggage do you have on there? I NEED that! Does it come off easy?
The top case?
It's a Givi, although I forgot the exact model (some old 30-ish liter model).
It comes off the mount (Givi Monorack for GS500) in a second, just turn the key and press the lower button (the upper is for case opening).

http://www.givi.it/index-en.php (http://www.givi.it/index-en.php)

Yea the big thing on the back  :icon_lol: Thanks. Sure beats a backpack!
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: xunedeinx on July 13, 2011, 09:34:35 PM
Can I get moved to the project section?
 
And all the noteworthiness is to Shepa on this build since he smoked my a** in finishing it first.  Ok, much respect to Tesla, but still.:bowdown:  And as soon as I get my bars in from xunedeinx  I'm going to get back on track.

They should be there.

I hate snail mail.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: cbrfxr67 on July 14, 2011, 12:39:53 AM
Got them in today xunedeinx!  Thanks again!  Amazing the difference in position.  Haven't done anything, just eyeballed it. 

Today figured I really needed to swap my oil pan.  My old one has a slight leak from a small hole.
(http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash4/268854_2247836918700_1331504559_2651348_6820614_n.jpg)
Okay it really has a hole the size and shape of Idaho in it!  In order for me to mount the headers and get on with it I need to fix this so got to it today.  Didn't finish but felt good getting back on the GS!
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: xunedeinx on July 14, 2011, 09:32:12 PM
How'd did you do that?

Termites?
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: cbrfxr67 on July 17, 2011, 04:35:33 AM
Today finished my oil pan install, then started on wiring.  Went pretty well.  Test routed the harness up to the front and then figured I'd swap to the clip ons and see how the wiring would fit.  Was good to get back into it after all the time I spent disassembling my old van.  I seem to have lost my fiberglass air box that I started so I'm going to pick up an F2 lower air box and then go from there instead of making my own lower piece.  I really like the clipons.  Thanks xunedeinx!!!!
(http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc6/268239_2257901410306_1331504559_2662185_613572_n.jpg)
(http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash4/283294_2257901210301_1331504559_2662184_3711986_n.jpg)
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: xunedeinx on July 17, 2011, 05:29:27 AM
Today finished my oil pan install, then started on wiring.  Went pretty well.  Test routed the harness up to the front and then figured I'd swap to the clip ons and see how the wiring would fit.  Was good to get back into it after all the time I spent disassembling my old van.  I seem to have lost my fiberglass air box that I started so I'm going to pick up an F2 lower air box and then go from there instead of making my own lower piece.  I really like the clipons.  Thanks xunedeinx!!!!
(http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc6/268239_2257901410306_1331504559_2662185_613572_n.jpg)
(http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash4/283294_2257901210301_1331504559_2662184_3711986_n.jpg)

They look sweeter on your bike then mine!
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: xunedeinx on July 21, 2011, 11:26:23 PM
cmonnnnnnn UPDATES! 8)
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: cbrfxr67 on July 22, 2011, 02:51:19 PM
Going to get on it this weekend,...picked up an F2 airbox off ebay, and I'm really hoping it comes in today so I can sew up my airbox pita this weekend.

,...Air box didn't make it in so I got back on wiring.  Put on the coils, figured out where they would mount best, did plugs and wires then worked on the clipons, put on the controls and grips: need some decent bar ends.  Rerouted some wiring, trying to get the components mounted right and save a nice spot for battery.  Pulled off rear tire and mounted the new sprocket and stuck new sprocket on the front, wrapped my clean new chain around and called it a day.  Tomorrow will cut to fit and get it lined up, more wiring and maybe start figuring out my undertail idea.

(http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc6/283225_2277473659600_1331504559_2689454_3056720_n.jpg)
(http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc6/217559_2277473539597_1331504559_2689453_4335764_n.jpg)

Thanks for pointing that out xune! :icon_lol: Didn't get as much done today (Sunday) as I wanted.  Finished up the chain and had to pack up.  Little disappointing cause I wanted to sit out there all day, but one step at at time is better than no step at a time.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: xunedeinx on July 24, 2011, 03:15:36 PM
well, its sunday, and no updates...fail time, or holding out till end of day???

 :cheers:
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: cbrfxr67 on July 25, 2011, 05:17:34 PM
(http://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc6/185259_2279636873679_1331504559_2694467_155734_n.jpg)
Finally got my airbox!  Funny how getting a part in will make the day better!
Planning on using this bottom piece of the airbox to mount to the carbs, figure out a lid/filter or seal the top and add on some pods or other configuration.  I'll have to see how much room I have and what I have to work with.  This has been a big stumbling block for me, so I'm hoping this'll help get things moving again.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: xunedeinx on July 26, 2011, 12:51:13 AM
Go to the local wally work, see if any panal filters are approx. close... then glass up the edges and make it work. when its done slap in a k&n high flow for whatever model panal filter you used, and have fun!
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: cbrfxr67 on July 27, 2011, 01:50:13 AM
Messing around with airbox this afternoon and the small base, which still wouldn't fit under the tank.  I didn't want to cut the base.  I was hoping it would fit and I could seal the top and use a pod off of the base or a flat filter on top like Xune suggested above.  Of course it wouldn't fit.  So being peeved and frustrated with this airbox pita I grabbed my die grinder and now the whole airbox will fit just fine.  Someone else was talking about this idea awhile back and I thought I might try it and see how it works out.
(http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash4/223815_2283546091407_1331504559_2701154_5166737_n.jpg)
Still won't fit
(http://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc6/283050_2283533771099_1331504559_2701128_2505126_n.jpg)
In case you ever wanted to see the inside of the tank,...
(http://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc6/216655_2283534051106_1331504559_2701130_4696540_n.jpg)
would love to weld that maw up where the airbox could fit too,...
(http://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash4/252090_2283533851101_1331504559_2701129_8333438_n.jpg)
Not my first choice of how I wanted this to go but using the tank as a cover and figuring out an auxillary tank set up might work.  Tank was really clean inside.  Oh well.  If I was an ace welder I might try to weld it back up but I'd probably ruin it.  The airbox in the pic isn't the one that I'll use, just an old cracked shell.  Didn't get to do much else except this today.

Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: ben2go on July 27, 2011, 03:13:54 AM
That explains alot.The GS tank body is three pieces,two halves and a bottom, and probably Jig welded to boot.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: Shepa on July 27, 2011, 07:04:42 PM
Messing around with airbox this afternoon and the small base, which still wouldn't fit under the tank.  I didn't want to cut the base.  I was hoping it would fit and I could seal the top and use a pod off of the base or a flat filter on top like Xune suggested above.  Of course it wouldn't fit...
(http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash4/223815_2283546091407_1331504559_2701154_5166737_n.jpg)
That was my original idea too, but there's just not enough space underneath the tank.
So... Tesla came to idea of making the intake housing out of stainless steel plate.

Here are a couple of pics, just to see how tight everything is.
The two ss pipes are not symmetrically welded to the box, because of fuel petcock and tank overfill drain hose clearance.

(http://img199.imageshack.us/img199/1838/dsc01074w.th.jpg) (http://imageshack.us/photo/my-images/199/dsc01074w.jpg/)...(http://img94.imageshack.us/img94/6676/dsc01073ql.th.jpg) (http://imageshack.us/photo/my-images/94/dsc01073ql.jpg/)...(http://img696.imageshack.us/img696/8389/dsc01072o.th.jpg) (http://imageshack.us/photo/my-images/696/dsc01072o.jpg/)...(http://img834.imageshack.us/img834/6518/dsc01065nz.th.jpg) (http://imageshack.us/photo/my-images/834/dsc01065nz.jpg/)

Later on, you need to weld a couple of bolts on top of the box, for lid fixation.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: cbrfxr67 on July 27, 2011, 07:52:51 PM
I'm going to try this with the tank cut out and use an auxillary tank inside the tank 'cover.'  Frustration in dealing with the airbox makes me want to push ahead and get more done and come back to this later.  I know this will limit my fuel capacity but I can move ahead from this step in the meantime.  Your base box is how I was originally going with my fiberglass piece but that (xunedeinx chorus) "FAIL!" didn't work.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: xunedeinx on July 27, 2011, 09:36:25 PM
I'm going to try this with the tank cut out and use an auxillary tank inside the tank 'cover.'  Frustration in dealing with the airbox makes me want to push ahead and get more done and come back to this later.  I know this will limit my fuel capacity but I can move ahead from this step in the meantime.  Your base box is how I was originally going with my fiberglass piece but that (xunedeinx chorus) "FAIL!" didn't work.

Drive down here to FL and ill do it for you.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: cbrfxr67 on July 28, 2011, 01:14:27 AM
(http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash4/267308_2286251999053_1331504559_2704054_448286_n.jpg)
Just worked on getting the rust off my header today.  Nothing spectacular.  Painted rust eater on it, which turned it all black, but that was about it.  Ground it all off and recoated it with more rust eater and that was it for this afternoon.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: xunedeinx on July 28, 2011, 01:59:56 AM
That thing would look good with a sporty muffler sticking out the back end of it.
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: Chancegs1996 on July 30, 2011, 06:39:35 PM
I found a good way to get rust off... Get some tin foil and wet it down, the bunch it up and ur good to go, all u need is a little elbow grease and u can get all of that crap off!! Lovin how the bikes lookin!!!  :thumb:
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: cbrfxr67 on July 31, 2011, 03:04:50 AM
Today,...finished knocking off the rust from the header and sprayed it with some high heat black, then worked out more wiring, mounted an old cbr kickstand to replace the giant ogre-club like kickstand that comes standard on the GS, annnd cleaned up some parts to use, namely front sprocket cover.  I picked up a box of miscellaneous parts and they looked like they'd been dunked in a grease-mud bath.  At least under all that gunk they were in good shape.
(http://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc6/183967_2293396137652_1331504559_2713456_6475131_n.jpg)
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: xunedeinx on August 01, 2011, 10:33:21 PM
Today,...finished knocking off the rust from the header and sprayed it with some high heat black, then worked out more wiring, mounted an old cbr kickstand to replace the giant ogre-club like kickstand that comes standard on the GS, annnd cleaned up some parts to use, namely front sprocket cover.  I picked up a box of miscellaneous parts and they looked like they'd been dunked in a grease-mud bath.  At least under all that gunk they were in good shape.
(http://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc6/183967_2293396137652_1331504559_2713456_6475131_n.jpg)

They look SCHAWEEEETT!
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: cbrfxr67 on August 02, 2011, 01:56:45 AM
(haha xune)
Today put the header on and wrestled with the removable subframe to get it back in place.  Seems with the oil pan, clearance is really tight now.  Also my header is right up underneath the oil pan with microscopic clearance.  I will have to figure something out there, or roast my oil with exhaust heat.  That was all I did for the evening.  Sheez it was hot today.
(http://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc6/285248_2298412063047_1331504559_2722957_6839613_n.jpg)
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: xunedeinx on August 02, 2011, 07:37:57 PM
(haha xune)
Today put the header on and wrestled with the removable subframe to get it back in place.  Seems with the oil pan, clearance is really tight now.  Also my header is right up underneath the oil pan with microscopic clearance.  I will have to figure something out there, or roast my oil with exhaust heat.  That was all I did for the evening.  Sheez it was hot today.
(http://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc6/285248_2298412063047_1331504559_2722957_6839613_n.jpg)

Heat up the header pipes with a torch, and bend it a few degrees.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on August 08, 2011, 11:12:20 PM
Today took a day off from work and dug into some carb work.  I needed to put together a new set after using an old junk set for mock up.  So disassembled a decent set for cleaning and run through.  Also bumped my triple down so I could set the clipons at the right heighth & replaced thermostat & housing since the old one was busted..  Got to see my old F3 project today when the buyer brought it by to BS for awhile. 
(http://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc6/284977_2315669374469_1331504559_2745939_5747080_n.jpg)
shaZamming hot today
(http://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc6/184079_2315669494472_1331504559_2745940_4284593_n.jpg)
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on August 10, 2011, 12:59:46 AM
Tonite, put in an hour to cleaning the carbs and started reassembly.  Carb cleaner stinks!

(Sunday) Finished carb assembly and had to mod the throttle cable to fit. 

Got some nifty pegs in from usdtmcs1 to replace those gargantuan stock mushroom obscenities too.  Will have to modify them slightly to get them to work but I like them.

(Monday) This evening installed carbs and got that almost sewed up.  Wish I had more time each day.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: xunedeinx on August 11, 2011, 05:36:54 AM
Tonite, put in an hour to cleaning the carbs and started reassembly.  Carb cleaner stinks!

Dirty carbs stink even more!
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: steezin_and_wheezin on August 17, 2011, 07:21:41 PM
anymore progress?

this thing is going to be a beast once its all buttoned up
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on August 19, 2011, 02:51:08 PM
(http://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash4/296687_2343012538031_1331504559_2782024_559997_n.jpg)
Finished with carbs & airbox, clutch cable set, fixed header problem of it being too close to the oil pan, temporarily mounted ignition (zip ties are my friend) and started on more wiring.  Going to focus more on getting it fired up and running and then go back to body work and how it is going to look.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: xunedeinx on August 19, 2011, 08:42:37 PM
If this thing works out well, how much for a conversion?

I WANT ONE!
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on August 19, 2011, 09:54:51 PM
xune, you should just stuff a fat FI 900 in yours!  Oh and do a build thread with lots O' pictures!
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on August 21, 2011, 03:05:12 PM
Nothing to update this weekend.  Towed my older old van to the 'shop' and pulled the engine/trans to swap in my newer motor/trans.  Got to get my bike hauler back on the road,.....
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: xunedeinx on August 23, 2011, 05:46:55 AM
xune, you should just stuff a fat FI 900 in yours!  Oh and do a build thread with lots O' pictures!

If I had the space and experiance, I WOULD!

The engine and mechanics side of it, I could pull off. The frame fabrication I could do the measurements and get a jig made up, but I wouldn't trust my welds.

If I did that id stick on a rear from an SRAD and a front end from a GSXR1k, and beef up the origional frame...

I might as well buy a small displacement bike with an aluminium frame and do the same thing to it except TIG it up. Itd be lighter = More badass!
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on August 23, 2011, 02:57:28 PM
I think you're right xune.  Yesterday a guy I know brought his gsxr 1000 engine that he bored out, over for me to check out.  I swear that thing is tiny, much smaller than my 600 engine.  I seriously want to try to build something with one of those next.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on August 23, 2011, 08:04:01 PM
Well, after two months of riding the project bike, I must confess one downside only...

Those Chinese gauges are complete piece of crap.
First of all, the speedo is showing cca 15kph less than actual speed (but I'll work that out), but the major thing is... the scale is made of paper only, no plastic at all, so it warped so much under the hot Mediterranean sun that the tacho needle is tending to stuck.
GRRRRRRRRRRR!!!!!!!!!!! And I left the five star feedback on eBay... I'll change my nick to "El Stupido".

Anyway... tomorrow I gotta take 'em apart and make the scales the way they were supposed to look like in the first place.
When I'm at it, I'll maybe put some LED bulbs instead of filament ones.

And yes... no videos yet. Guess I'm too lazy for that, sorry.

BTW, since cbrfxr67 is taking his time, how bout splitting the topic in two, so I could post some additional pictures and maybe even videos?  :icon_mrgreen: :icon_mrgreen: :icon_mrgreen:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on August 24, 2011, 05:13:55 PM
Szucks on the gauges not holding up to expectations.  I'm probably going to do an inductive tach and use the GS speedo on the F2's gauge harness/lights.  Just found a cheap gauge set on ebay, F2 complete, which will really make the wiring a zillion percent easier.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on August 24, 2011, 10:30:39 PM
Phew... just finished the gauges adaptation...

Well, I thought about explaining what I did, but I've just realised I'm too tired to type.

Gotta get up early, to mount 'em on bike and of to work...

Later. G'd nite.

 :thumb:

Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on August 29, 2011, 08:42:57 PM
Shepa, still waiting on that update to see what you did.
Annnd, progress has halted on my GS til I get my bike hauler (van) running and then I'll get back on it.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: xunedeinx on August 30, 2011, 06:46:41 AM
Awww, cmonn
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on August 30, 2011, 03:57:25 PM
Shepa, still waiting on that update to see what you did.
Annnd, progress has halted on my GS til I get my bike hauler (van) running and then I'll get back on it.
Nah... not much of an update, I just combined GS tach scale with "chin-honda" electronics, managed to save the temperature gauge...
and inserted the complete GS speedo into the "chin-honda" housing (basically the mechanics are identical, it's just that I have a little bit more faith in Japanese instrument), to finally have the correct kph readings, and no scale warping anymore.

(http://img3.imageshack.us/img3/7398/dsc01167cz.th.jpg) (http://imageshack.us/photo/my-images/3/dsc01167cz.jpg/)
Salvador Dali was here...  :icon_mrgreen:

(http://img825.imageshack.us/img825/5688/dsc01171o.th.jpg) (http://imageshack.us/photo/my-images/825/dsc01171o.jpg/)
Nevermind the light protruding the speedo, that's the side-stand light, it goes off when the stand's up.
And no, the chinese (white) needle won't go on Japanese speedo... the jap-shaft is 0,2 milimeters thicker.
 :sad:


Also, since the vacuum fuel tap is not so airtight...
Hell, since I'm at the keyboard, I'll tell the complete story...

Two weeks ago, got up in the morning, sat on the bike, ready to roll to work, pushed the starter button, nothing happens.
And I mean nothing. At all. Just a click. Then again... only one "click".
At this time, a faint smell of petrol should've give me a clue, but GS' always smell of petrol so... I didn't notice anything unusual in that.  :icon_mrgreen:
OK, I'm thinking, maybe the battery's dead, I'll push-start it in no-time.

Right... I've pushed it down a short slope (as usual when the battery's low - at winter time mostly), released the clutch, but the rear wheel instantly blocked.
WTF?! OK, so I went further down the slope... getting some speed now, again, released the clutch in (dunno) second or third gear...
Rear wheel is solid blocked again!!! Well, the moron in me started to jump on backseat to give it more grip, but to no avail... after 40-50 metres I gave up.
Phoned Tesla, and he immediately said: "Your crankshaft's blocked, engine seized."

Fck, I instantly realised what happened... the smell of fuel, the starter not turning, the blockage of rear wheel... the icy cold sweat started to pour down my face...
Hydrolock!

During the night, the vacuum fuel tap must have gone bad, allowing one carburetor (the one that was overflowing for no particular reason) to fill one of the cylinders.
Later, when I lifted the tank, I saw that airbox is half full of petrol (construction flaw... Tesla forgot to drill the drain hole after airbox-mod).

Anyway, I closed the tank petcock, and went to work on foot, just to wear off the anger...
I was cursing myself for the whole day for hydrolocking the engine, possible breaking of the con-rod, valves, and damaging the crankshaft during push-starting...

I came home after the work, feeling like pissed flower, and went to organise hauling over to Tesla's garage...
Just out of curiosity, I tried to crank the engine, since I hoped most of the petrol in the cylinder would be in the oil pan by now...
It sparked in millisecond, and went on to idle, purring like kitten.
Well... the stone that fell off of my heart almost smashed my foot...

If something's bent, it's not showing, and I'm not too curious to go searching for it. No suspicious sounds, no lack of power... nothing unusual.
I just changed the oil (yep, filled with half a liter of petrol), installed electric fuel valve between the vacuum fuel tap and the carbs, and the bike's fine ever since.

I must be thankful, because I have a friend that has an old Honda CB900... and couple o' years ago, he also tried to push start it while flooded with fuel.
The problem was... the three cylinders cranked (ignited) forcing the fourth con-rod to snap and punch a hole in the engine block.

So... that's it for now, I'm enjoying the ride every single day, and the thoughts of selling the GS are now long gone and forgotten.  :icon_mrgreen:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on August 30, 2011, 08:41:07 PM
(http://i682.photobucket.com/albums/vv188/TattooTaffy/popcorn.gif)
Good read Shepa!  I like how Tesla knew what it was on the phone!
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on August 31, 2011, 05:33:39 AM
Good read Shepa!  I like how Tesla knew what it was on the phone!
Yep, the man knows. :bowdown:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: xunedeinx on September 12, 2011, 03:38:00 PM
Nothing new guys?
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on September 12, 2011, 05:25:28 PM
Hell yea, installed my engine & transmission then had to rewire the 88 harness to the newer 92 computer and figure out wtf I forgot since it wouldn't run.  Figured that out Saturday and reconfigured all those wires, consolidated them all together, put the dash back together, sewed up odds and ends and fired it up!  Ran good but still have some more things to tidy up.  Oh, wait, you were talking about the GS weren't you??  Uhh, errr, well, I, am going to get on it here shortly since the bikehauler is coming together!  :D
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: xunedeinx on September 13, 2011, 12:26:01 AM
Hell yea, installed my engine & transmission then had to rewire the 88 harness to the newer 92 computer and figure out wtf I forgot since it wouldn't run.  Figured that out Saturday and reconfigured all those wires, consolidated them all together, put the dash back together, sewed up odds and ends and fired it up!  Ran good but still have some more things to tidy up.  Oh, wait, you were talking about the GS weren't you??  Uhh, errr, well, I, am going to get on it here shortly since the bikehauler is coming together!  :D

Allright, but im still waiting for some youtube videos of the 4cyl gs500!

Which makes me think...

we have 500cc's, 35hp, sportbikes have 600cc's, 120hp... I find it hard to believe that 100 cc's gains you almost 100 hp. Where are all our missing horses!?
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: kml.krk on September 13, 2011, 06:30:47 PM
Allright, but im still waiting for some youtube videos of the 4cyl gs500!

Which makes me think...

we have 500cc's, 35hp, sportbikes have 600cc's, 120hp... I find it hard to believe that 100 cc's gains you almost 100 hp. Where are all our missing horses!?

So looking at the factory mentioned HP and Wiki, GS has:
Horsepower: 1989–1996 52 hp (38 kW) @ 9200 rpm. 1997–2009 47 hp (34.3 kW) @ 9200 rpm.

CBR 600 from 2009-2011 (info also from Wikipedia)
102.2 hp (76.2 kW) @12,600 rpm

MATH (compared 2 newest bikes / 2011):
102.2 - 47 = 55.2

So the difference is not 100 HP but 55.2 HP.
And it all comes from about 20-25 years of advancement in technology + different engine configuration.
Remember that GS from 2011 still uses powerplant designed years ago (First GS500E was introduced in North America in 1989) and it remained virtually unchanged since then, with the exception of few minor details.
On the other hand bikes like CBR600/GSXR are modified almost every year and new technologies are introduced in them.

On average if you multiply a gain of 2HP per year in modern sportbikes you get:
2[HP] * 25[years] = 50HP[gain]

Disclaimer: I have no idea what I am talking about but it seems very logical.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: BaltimoreGS on September 13, 2011, 10:55:07 PM

Which makes me think...

we have 500cc's, 35hp, sportbikes have 600cc's, 120hp... I find it hard to believe that 100 cc's gains you almost 100 hp. Where are all our missing horses!?

The GS has a really antiquated air cooled parallel twin cylinder design with only 2 valves per cylinder.  The now defunct Ninja 500 of the same vintage had a liquid cooled parallel  twin engine with 4 valves per cylinder and made about 60hp.  Lack of design updates has left the GS500 in the past.  It's not such a bad thing though, there are plenty of useable parts floating around relatively cheap   :thumb:

-Jessie
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Phil B on September 15, 2011, 09:30:46 PM
Interesting points, BaltimoreGS.

On the flip side, there is the BMW twin,  800 (S, ST, gs), which gets 80hp.
water cooled, 4 valve. but gets BETTER mpg than our gs500. Yet its a little heavier.
kinda impressive. wonder just how "old" that tech is.

But on the downside, 4x the price :D
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: crzydood17 on September 26, 2011, 07:58:45 PM
we just need to find a cheap easy 4 valve swap, lighten up the valve train and spin to 13k and we should be in the 60 hp range! A nice cam and some performance carbs wouldn't hurt either :(
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on October 03, 2011, 02:33:59 PM
Before,..
(http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash4/305430_2494589287355_1331504559_2934742_162577987_n.jpg)
Finally finished the bikehauler, well as far as the engine swap goes and spent the day organizing and getting ready to get back on the GS.  Still somemore cleaning to do but I'm ready to start on the GS and get it fired up and running.
After,...
(http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc7/298126_2494588847344_1331504559_2934741_448917334_n.jpg)
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on October 03, 2011, 05:59:45 PM
Phew... I was afraid you gave up...  :icon_mrgreen:

Nothing new on this side of Atlantic... just cruising as any other day...
In a couple o' days I'm getting an R6 rear shock...
And a R6 front end (one fork leg a bit bent, cracked lower triple, but it's for free, so I don't care), so I'll see what could be done with it (if anything).
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on October 03, 2011, 07:13:28 PM
R6 front end, R6 rear shock=FREE is good!  (Tesla magic or Shepa handiwork going to make this happen???)  :icon_mrgreen:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on October 09, 2011, 01:59:55 AM
(http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash4/311849_2514642988685_1331504559_2951451_1083066793_n.jpg)

(http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash4/300340_2514643348694_1331504559_2951453_1596510657_n.jpg)

(http://hphotos-iad1.fbcdn.net/hphotos-ash4/301616_2514643188690_1331504559_2951452_427005034_n.jpg)

Today started on mounting the radiator.  At first I thought it was going to be too tight.  Kept maneuvering it until I found the sweet spot.  Had to make some brackets to hold it so used some light aluminum and bent it out.  Prob paint it black to conceal it better eventually.  Also hooked up some gauges and controls into the harness, just for test starting.  Also filled up the crankcase with marvel mystery oil to check for leaks since I replaced the pan recently.  I think that's all I did today.  Oh and I pulled off that stupid fender.  The GS fender looks retarded to me.

Relating to the 'tools thread' BaltimoreGS started, this little led light is made by Central and is the best one I've used yet.  It flips around on the square base and has a magnet and hook.  Only 20 bucks and runs for 4 hours, but the best thing about it is that it doesnt ROLL around when you set it down.  I hate that and want to chuck round lights across the yard when they roll and won't stay lit on what I need to see..
(http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash4/302232_2514700870132_1331504559_2951487_484534815_n.jpg)
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on October 10, 2011, 08:59:22 AM
(http://2.bp.blogspot.com/-_cR7lmjf1D8/TaZigmVpmvI/AAAAAAAABqg/R1dPERYoXkY/s1600/harris.jpg)

Go on, move it, move it!!!

 :icon_mrgreen:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on October 16, 2011, 01:48:33 PM
Yesterday, drained the Marvel (no leaks), went and got a battery and oil, hooked everything up and kept popping the main fuse.  Pulled out my handy Lisle bypass starter and cranked away.  It didn't start because I haven't hooked up my auxillary tank but I was looking to see if it would crank..  Seemed fine, just like it worked before I stored it a few years back.  Next is to connect some gas, check if the carbs leak and see if it will fire up.  The main fuse problem, I'll have to figure out too.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: gtscott on October 17, 2011, 06:18:57 AM
did you connect a positive wire to earth anywhere?
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on October 19, 2011, 01:49:57 PM
Worked on my electrical problem last night.  Have two solenoids for the 600 but I seem to remember both of them being shot.  Have two for the GS so initially used the GS' but kept popping the fuse.  Tried both of the 600 solenoids and neither worked so will have to get another one.  Not sure what is different about the GS' models, they fit the 600 harness.  Going to look around a bit on the web today.

After work went back to the solenoid.  Found no power getting from the connector on the solenoid/fuse to the harness (?).  Hacked it and replaced it with another and power was there all the way to ignition switch but not to the starter button or lighting up gauge cluster.  Need more time to find the problem,...
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on October 22, 2011, 03:07:12 PM
Was gonig to start a thread on 'master link vs rivet style' chain link but saw it had been done before.  Had my master link break or come off and my chain flew off the back when I was riding home yesterday.  Luckily I wasn't going very fast or on the freeway.  Lucky too that I have the bikehauler running to where I could go get it.  I'll be getting a rivet tool here shortly though, just for peace of mind's sake, if not for safety.
(http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash4/296324_2564977447015_1331504559_2993692_1745522471_n.jpg)
On another note, got a new solenoid in, so will try that today and see if it helps any.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on October 24, 2011, 01:53:26 PM
Sunday, found that not only was my solenoid bad the ignition switch was bad too.  Had another on hand so swapped it in and gauges lit up.  :thumb: Starter switch turned it over nicely.  Today going to add gas and see how it runs.
(http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc7/300633_2571996142478_1331504559_2999927_1889884147_n.jpg)
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: xunedeinx on October 24, 2011, 02:12:04 PM
Vids!

 :cheers:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on October 31, 2011, 01:33:13 PM
Mostly did carb work over the weekend as I kept springing leaks.  Finally yesterday took everything off, broke the bank apart and replaced the o-rings between each carb.  Reassembly was the best yet and I think I finally found where the ___-ing leak was.  Time allowing, reassembly, start up, might as well balance the carbs while everything is off and hopefully upswing into getting fuel system sewed up.

**Wednesday pm: Got it back together, minus the airbox so I could sync and starter fluid gets it going but then it dies.  This weekend will try to work out the idling problem.  Sounds ridiculously loud with no muffler on it.  :2guns:
Title: Re: 1996 GS500 Basket Case Build into a GS600RR
Post by: yamahonkawazuki on November 06, 2011, 11:19:40 AM
I'm not sure how to incorporate the pod filters.  I know they do it on the sprint cars that use these engines but I've never seen the way they are adapted to the carb.  I should look into that.  And definitely will do a rear swingarm swap eventually.  These tires are in like new shape, but when they get worn out I want to do the swingarm swap.  I already have an F3 swingarm but I believe it is too wide to fit (9").  Also, I'm sure I will do the front end change to get rid of those awful gs handlebars.  Need more time in the day!
could mod the tank somewhat. a c-notch in the underside.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on November 07, 2011, 04:40:36 PM
Thanks for the tip YHKS.  I'll get back to the tank eventually; right now using auxillary tank.  This weekend worked on carbs.  My boots were dried up and not sealing carbs to engine, which was messing up my vacuum.  Fixed that and started on the first crank.  I ran it for about a minute just to see if it would idle and it seemed really good for no tuning yet.  I didn't have the cooling system hooked up so connected my hoses and filled it up and ran it again with same good results.
Next will be to balance the carbs and work on tuning them to run better.  Then I'll redo my chain, finish the foot pegs I received awhile back.  When I get that far it'll be rideable, well maybe if I use that tip from YHKS.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: ohgood on November 09, 2011, 01:42:23 AM
Was gonig to start a thread on 'master link vs rivet style' chain link but saw it had been done before.  Had my master link break or come off and my chain flew off the back when I was riding home yesterday.  Luckily I wasn't going very fast or on the freeway.  Lucky too that I have the bikehauler running to where I could go get it.  I'll be getting a rivet tool here shortly though, just for peace of mind's sake, if not for safety.
(http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash4/296324_2564977447015_1331504559_2993692_1745522471_n.jpg)
On another note, got a new solenoid in, so will try that today and see if it helps any.

excellent choice of a cheap-ass-parts-are-everywhere-and-interchangable-shitbox-van for hauling your cool stuff around. astros were great except:

driver leg room
passenger leg room
stupid engine shroud
stupid radio 3 miles from the driver
rear doors bouncing off the taillights
stupid f%$king spark plugs under 33 inches of cats'ass insulation, and said engine shroud
unfucking possible seats
are you ffucking kidding me with the berretta door handles ? really ? GM ?
huge plastic door panels
shaZam! plastic dash
grill, or as we called it "the basketball deflector shield"
paint pealing everywhere
anti-WTF_CRASH-brakes that sometimes work, sometimes not so much

and i do mean great:
4.3 liters of smooooooooth interstate powa
fiberglass leafs
choke a horse AC
burn the tires for a week (see 4.3 liters of smoooooth)
power steering a gnat could turn

anyway, on with your thread, that's a kickass van  O0
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on November 09, 2011, 05:11:07 PM
I paid 200 big ones for the bikehauler.  It's actually my second Astro.  My first one I drove for a few years then stripped it (r.i.p.) and put its engine/trans into this one.  It's an 88 and just right for hauling bikes and crap.  I wasn't sure my bike'd fit with the windscreen but it went right in.  Great list ohgood!!  That made my day!

**and last night started pulling my bike apart.  Want to clean out my carbs and check fuel system over and I also need the cylinder adapters to sync the carbs on the GS.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on November 11, 2011, 03:19:33 PM
Last night pulled the adapters off my bike and threaded them into the GS.  Actually broke one and had to use an easyout.  Luckily soft brass comes out without too much hassle and I had an extra one.
 
(http://hphotos-iad1.fbcdn.net/hphotos-ash4/298069_2646479484515_1331504559_3055969_1098788651_n.jpg)

After got gauges set up messed around getting them sync'd.  Went quite well, rev'd nicely, sounded great, although neighbors probably don't agree.

(http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc7/380023_2646478564492_1331504559_3055968_1509056256_n.jpg)

Still need more time to dial them in.  Headers were smoking up the garage so I stopped before someone called the fire department.  heheh

(http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash4/385536_2646479764522_1331504559_3055970_1502096349_n.jpg)

Also, going to pick up a 95 Katana tonight that we found for a couple big ones.  I figure at the worst we can pull parts, stick them on the GS and piece out the rest.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on November 14, 2011, 09:08:18 PM
Well Katana pick up fell through for one reason or another.  Got back to work Sunday, sync'ing and running it and was really happy with how things were going.  Sounded good, responsive, balanced well so I pulled adapters and gauges off and figured I'd get busy on exhaust.  My friend came over so I was going to start it for her to hear, and -click-.  Nothing.  I tried it again. -click-.  Starter was engaging but not turning the engine over.  wth.  For some reason I had a hunch, and cylinder one was hydrolocked.

(http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash4/388797_2664812782836_1331504559_3066506_788873374_n.jpg)

There it was, bubbling away and filling up the cylinder with gas.  SOAB.  So, going to pull carbs again and swap the float, go through number one and see if there is something obvious.  Sometimes I really loathe carbs.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on November 14, 2011, 09:46:04 PM
My friend came over so I was going to start it for her to hear, and -click-.  Nothing.  I tried it again. -click-.  Starter was engaging but not turning the engine over.  wth.  For some reason I had a hunch, and cylinder one was hydrolocked.

There it was, bubbling away and filling up the cylinder with gas.  SOAB.  So, going to pull carbs again and swap the float, go through number one and see if there is something obvious.  Sometimes I really loathe carbs.
Seems like a common issue with those F2 carbs, huh?  ;)

Just out of precaution, try installing an electric valve on the fuel line (like I did), so you'll be sure not to hydrolock it (at least while switched off).

Last week, my babe all of the sudden started sputtering while in 3rd gear way up in red line... so I freaked out that the timing chain jumped the tooth...
Tesla thought one of the exhaust valves snapped, so we tore half the engine down, checked the carbs, checked the sparks, checked the compression, checked the timing chain...

The last thing we did was pour some fresh fuel in it...  :icon_mrgreen:

The day before, I've sent Tesla's nephew to fill in a couple of liters (since the bike was on reserve, and we planned to sync the carbs)...
Apparently, he filled a couple of liters all right... except it was a diesel, not petrol.  :cookoo:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on November 17, 2011, 03:17:25 PM
Yes I need a Tshirt: "Everything I learned about carbs is thanks to my F2."  But, Diesel????!!  That's a whole lotta work for a brainfart!

Yesterday, pulled carbs, replaced #1 float/valve and put carbs back on.  Piston was at the top of the stroke so hydrolock wasn't that bad, took out plug and mityvac'd remaining gas out of cylinder, then turned over the engine a few times with plug out.  Oil level was okay and didn't smell like gas so I'm going to leave the oil change for later.  Will test out later to see if float/valve swap solved issue.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on November 28, 2011, 02:49:11 PM
Over the long weekend, put pegs on and modded shifter linkage to fit, bled rear brake -for some reason po must've unscrewed the bleeder valve, put nice new oring chain on since I stole the other one for my bike and worked on getting clutch cable adjusted right.  Shifted through gears ok but hard to get back into neutral so I think I need to get it adjusted right or simply swap over to 600 cable.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on December 04, 2011, 11:42:42 PM
Got clutch adjusted and realized I had reversed the gearing, so fixed that and had to mod my airbox just a bit to fit.  Had an annoying fitment issue (crankcase vent tube) that wasn't there before.  Fixed that, ran it and all seemed good.  Wanted to get a 'first ride' in and then it started raining.  After rain passed gave it a shot and putted up and down the road.  Something kept rubbing, and hitting a bump jolted the wheel into the radiator.  Nice.  So, with a bend in the bottom of the radiator I put it up for the day.  Need to figure out a better way to mount the radiator or a smaller radiator or maybe go back to my original idea of dual smaller sized radiators.  Other than that, felt really good to ride it finally.  Any ideas on the radiator issue would be appreciated. 
(http://a8.sphotos.ak.fbcdn.net/hphotos-ak-snc7/384086_2796556116337_1331504559_3121807_1384411072_n.jpg)
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: dohabee on December 05, 2011, 11:13:30 AM
How about longer and or stiffer front forks? maybe stiffer springs in the gs fork tubes?
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on December 05, 2011, 03:19:33 PM
Was thinking about that dohabee.  Shepa didn't have the same problem so perhaps my forks are worn out.  I haven't done anything to them yet, not even checked them out, probably should do that before reconfiguring whole radiator.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on December 05, 2011, 10:23:33 PM
Was thinking about that dohabee.  Shepa didn't have the same problem so perhaps my forks are worn out.  I haven't done anything to them yet, not even checked them out, probably should do that before reconfiguring whole radiator.
Come to think of it... I'd probably have the same problem if my forks didn't have inner spacers 35mm longer than original (more preload), so when they're bottoming out the fender's still way off the radiator (which Tesla mounted as far up the frame as possible, you saw the picture).
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on December 09, 2011, 10:43:17 PM
Picked up a dual radiator set up for dirt cheap and thinking of trying it out.  I am not sure if the capacity will be enough to cool the engine but side by side the two are near the size of the stock 600 radiator.  I'll probably try it just because I want to make it work.   :2guns:

(http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash4/385969_2846371441689_1331504559_3142047_111035269_n.jpg)

Saturday,...pulled radiator off and messed around with my dual radiator idea.  Shame when you work on something (brackets for radiator) and then come back and toss them all to the side cause you need to figure something else out.  Dual radiators may work.  Hose routing is kind of annoying.  Going to go by hardware store tomorrow and see what kind of adapters I can find for hoses.

(http://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash4/377923_2846371881700_1331504559_3142048_817224770_n.jpg)
(from wheel, doh!)
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on December 15, 2011, 02:51:58 PM
Experimented with dual radiator set up.  I kind of like it just because it looks different.  Still need to get some hoses routed right and then make brackets to hold them.  I'll post pics when I get it finished.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on December 16, 2011, 12:50:06 PM
C'mon dude, this is taking way too much time, get it on the road already!!!

 :thumb:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on December 21, 2011, 03:46:23 PM
I'm aiming for spring honestly.  I still have alot to do Shep!
Last night worked on making brackets for dual radiators.  I don't know what you guys are going to think about these.  I'm not sure what I think, yet.
After that, start figuring out gauge and controls set up, then tank nightmare, then back to bodywork and finishing that, then undertail, and finishing touches and should be done.  What could go wrong between now and then?  Surely nothing!
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on December 21, 2011, 10:21:52 PM
I'm aiming for spring honestly.  I still have alot to do Shep!
Last night worked on making brackets for dual radiators.  I don't know what you guys are going to think about these.  I'm not sure what I think, yet.
After that, start figuring out gauge and controls set up, then tank nightmare, then back to bodywork and finishing that, then undertail, and finishing touches and should be done.  What could go wrong between now and then?  Surely nothing!
Tell you what... pay Tesla a round-trip airplane ticket, and he'll do it for free in a couple o' days.  :icon_mrgreen:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on December 23, 2011, 10:18:23 PM
With his eyes closed too I'm sure!   :icon_mrgreen:

Worked on my radiator brackets more and almost finished today.  Just using mild steel, (actually handles off of roll around battery chargers from work) bending and drilling mounting holes.

(http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc6/166960_2936504854968_1331504559_3183760_1806444709_n.jpg)

And, here's preliminary,....

(http://a8.sphotos.ak.fbcdn.net/hphotos-ak-snc7/400344_2936505734990_1331504559_3183763_2032768159_n.jpg)

(http://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc7/391050_2936505654988_1331504559_3183762_1921741869_n.jpg)

They are about as wide as the enginecase.  So though they look huge, really they aren't that wide.  I'm still adjusting and haven't got them comlpetely set yet.  I'm thinking of eventually making some scoops or shrouds but that'll be later.  While side by side, they are almost the size of the stock 600 radiator, I don't know how they will cool in Texas summer heat.  They'll both have a fan.  Only summer'll be able to test their cooling ability.  Please comment on if you hate 'em, like 'em or whatever.  Like Tombstones81 said, sometimes you keep posting and noone says anything so you wonder if you're writing it up badly or what,.....either way, still working on it.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: comradeiggy on December 24, 2011, 07:04:49 AM
That setup looks pretty sick IMO, I'd just be worried about a rock or something getting kicked up into it.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on December 24, 2011, 10:14:46 PM
Hm... Looks rather interesting, and the width gives it some muscle look.
But what about the fairings clearance?
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: dohabee on December 25, 2011, 11:11:26 PM
Looks pretty cool, is it going to fit under the bodywork?

Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on December 26, 2011, 02:33:42 AM
Took it out tonight, on low traffic Christmas Day, and drove around.  Feels so different from my bike, still scary fast.  Got my brackets sewed up finally and next will mount the fan(s).  Had problems getting the angles on right side.  Then saw the unused engine mounting point on the removable frame piece and used that to get it mounted solid.  Hopefully tomorrow I'll get more time to work on it.   :)

Thanks Comradeiggy.

Shep, and Dohabee,...I'm not sure about body work.  Maybe some shrouds, SuperDuke Ktm style on the sides?  I'll figure that out later.  Pretty sure stock body work isn't going to work.  Or,...would it, with some modifications?  That might be alot more interesting.  Alot of work but could be worth it after I get it road legal.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: comradeiggy on December 26, 2011, 04:16:57 AM
I just thought of something. Even though the radiators aren't quite the size of the stock one, since they are out in the air flow away from the (hot) engine and headers, with nothing behind them to cause back pressure and what not, they will probably have significantly more cooling power than the stock radiator even without fans.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on December 30, 2011, 05:01:48 PM
I hadn't thought of that but I'm hoping you're right.  I accidentally dumped it (didn't put kickstand all the way down oops) but it didn't bend anything.  I thought for sure I was going to have to redo brackets or something.
Mounted my fan and then messed around with some muffler ideas.  Thought of hacking the old gs exhaust up and making something but seems a shame to chop it up and lose my wall decoration.  I want it to be Seamax style but not sure if anything'll fit right, with the way my header is.  Actually thinking of trying to make my own after looking at some guys on the web who made their own.  Just a short baffle on the inside with some packing, weld it up and stick it on.  How hard can it be?   :2guns:
Turned to controls and dash and realized crossing over from the 600 harness to GS control wiring was going to be a real pita.  I don't want to, but going to go with the cbr controls to match the harness.  oh well doing that this weekend.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on December 31, 2011, 11:55:38 PM
Worked on getting the controls and wiring sewed up on the front.  Really disappointed to have to take airbox off again.  erg.  I didn't have a throttle tube with me, so stopped on the controls and taped up wiring and mounted ignition.  Zip ties have been holding everything for awhile.  Made some dinky brackets to hold the ignition at a nice angle.  NOooooo of course it didn't fit the stock location.  I didn't cut it down to match the ignition because I may need to mount more pieces to these later.  If not I'll cut them down and make them look nice.  Seemed like I put a lot of time into this today.  That or time slipped by quicker than I expected.
Thinking of how to do the gauge pod.  Sure a smaller gauge setup is sexy but I'd like to use the 600 gauges and get on with it.  Debating cutting them down and mounting them tight on the triple.  Wish I had some xune-like skills and could fiberglass them into the top of the tank.  That'd be much more interesting!

(http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc7/398658_2988731600604_1331504559_3214363_1554715489_n.jpg)
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on January 04, 2012, 03:27:21 AM
Tonite swapped the controls, throttle cable and choke cable.  I'm not a big fan of rework but it wasn't that bad, probably much better than trying to rewire the GS controls to match the 600 harness.  So, got that done and called it an evening.  Really made a difference up front, eliminating unneeded wiring.
(http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc7/383965_3012655038675_1331504559_3230414_1993904668_n.jpg)
Starting to look for some headlight ideas and thinking about what to do with that jacka** tank.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: xunedeinx on January 05, 2012, 12:09:51 AM
Wish I had some xune-like skills and could fiberglass them into the top of the tank.  That'd be much more interesting!

Its easy!

Get some styrofoam, mold/cut/trim it to the look you want on the tank, than cover your tank COMPLETELY with tin foil, no holes or leaks, Lay the glass over it, resin it, wait for it to cure, remove it, pour gasoline on it to melt away the foam, and lay your final glass layers on the inside.

Than, just finish the peice, find a way to mount it, and your golden!

That easy...heh
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on January 05, 2012, 06:32:08 PM
Thanks xune.  Really giving me some ideas with that.  I still have to figure out what to do with the tank anyway, so might try it!
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on January 06, 2012, 03:08:59 PM
Last night messed around with the tank and found that the auxillary tank will fit under the tank.  So with that, made a nifty bracket for it and though it isn't the best option, for the moment will run with it.  Xune got me thinking, to set it up this way and then fiberglass a new shape, make a new tank (maybe weld something up to fit the dimensions) under that and go with it.  For now though, will use auxillary tank under original tank 'shell.'  It holds about a gallon and a half at most.  Good thing I'm not commuting across Croatia. ;)
(http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash4/384534_3030603487375_1331504559_3237349_1007211627_n.jpg)

(http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc7/396847_3030601727331_1331504559_3237346_733491297_n.jpg)
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: xunedeinx on January 11, 2012, 06:01:56 PM
Another crazy idea for you...

Take your stock tank, and build the airbox into the front half of it, and a gas tank into the rear half, and have it hinge up in the front, kind of like the hood on a caddillac with the pnumonic pistons.

It'll get rid of having to use the stock airbox, and consolidate it into the stock gas tank..

It'll look stock, and be functional. And, you should have at least 2 gallons of gas.

If you need more, buy an auxillery 2 gallon tank, and find a way to put it under the seat!
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on January 11, 2012, 06:29:58 PM
You always have good ideas Xune.  I'm definitely not finished with the tank set up.  Just wanting to get it moving.  I figure that area can be modded later after 'finishing' because the tank dimensions won't change and I can sew up everything around it.
Worked on battery box and mounting bracket, made out of a scrapped battery charger handle and a broke inverter.  I probably spent way too much time on it but was having fun with it.  For some reason I really have fun bending and maneuvering brackets to fit where I want them to.
(http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash4/403722_3067574451626_1331504559_3252597_65362144_n.jpg)
Test fitting bracket for battery box
(http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash4/406399_3067573251596_1331504559_3252596_1968307873_n.jpg)
Mounts to the engine hanger location on the left side.  I put a piece of rubber in the bottom to keep the bolt heads from rubbing through the battery casing.
Also got my muffler in today that Redge posted up in another thread.  It's shorter than I expected and that's a good thing.  Going to see if it'll work.

And is it just me or was the forum down for two days?!  ShaZamming Buddhalovesyou

Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on January 13, 2012, 04:07:05 PM
Last night dug out the basket case and got some parts for Tomb and his project then stuck the muffler on to see how it looked.  That was all I did.

(http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash4/393664_3080900264763_1331504559_3257127_1916727385_n.jpg)

Also, got in what I might try to use for a headlight!  Off a Snowmobile!  Sweet!
(http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc7/408948_3082053533594_1331504559_3257515_295230448_n.jpg)
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on January 18, 2012, 02:25:49 PM
Put the exhaust on over the weekend and ran it.  Sounds much better with the exhaust.  Still loud but not as raucous.  I'll post a clip when I fix my fuel delivery issue.  Was starting to move along and noticed a drip, found auxiliary tank had a mysterious hole appear in it. (?)  I may have dropped it or something.  So at this point of frustration I decided to go ahead and make my tank.  Cut out a test pattern, then mocked it up in steel plate, tack welded it together, and tack welded in bottom bung.  That's where I'm at now.  Tonight hope to get fill cap hole cut and cap test fitted, along with more welding up the seams.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: xunedeinx on January 18, 2012, 04:34:47 PM
Pics and video!

I want to hear it!

I want to make one...
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: xunedeinx on January 18, 2012, 04:47:09 PM
Hey brother, can you do me a favor?

Make a paint drawing of both motors, the gs500 one, and the f2 one for me?

Depth, width, height, length?

I want to see how the dimensions of the i4 compare to the twin.

Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on January 18, 2012, 04:54:28 PM
Couldn't stand the air filter issue (no air filter  :icon_mrgreen:), so I just ordered K&N drop in, to see how the thing's working.
Maybe then I'll find the time to shoot some videos myself. :icon_mrgreen:

Anyway, that R6 forks I was talking about are of no use, since the donor bike was totalled, and the rear shock is of an "eye-eye" type, so I'd have to manufacture some kind of linkage to install it. Later. Maybe in the spring.
Now I got something different on my mind...

RGV250 forks.
Anyone used them?
Will they fit on GS?
It's the length that's worrying me, so anyone with RGV experience... be my guest.

Thnx!

Hey brother, can you do me a favor?

Make a paint drawing of both motors, the gs500 one, and the f2 one for me?

Depth, width, height, length?

I want to see how the dimensions of the i4 compare to the twin.


You got my pictures in this thread, both engines side by side, maybe it helps.
The F2 fits almooooost to the GS mounting points.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: xunedeinx on January 18, 2012, 05:27:19 PM
Yea, I just went back and saw the pics. It looks a lot smaller than the gs's twin..

Is it possible to find carbs that fit the f2 that are side draft? Use 2 sets of gs carbs?
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on January 18, 2012, 05:36:41 PM
Yea, I just went back and saw the pics. It looks a lot smaller than the gs's twin..
Yes, smaller and lighter.  :thumb:


Is it possible to find carbs that fit the f2 that are side draft? Use 2 sets of gs carbs?
Dunno, once you put the F2 engine inside frame, the usable space all of the sudden dissapears, and everything is very tight to work around.
And besides, I've bought a complete F2 engine, so I didn't bother to think about GS carbs.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on January 18, 2012, 07:03:03 PM
xune, you have to go answer the 'what the shaZam does your username mean' thread first. 

And my GS motor is just a basket case o' parts.  I can say that the F2 engine is obnoxiously wide.  I like it though.  I'd seriously do a FI engine swap before I did another one like this.  The 1000 engines are tiny compared to the F2 boat anchor.  A guy I know let me manhandle his gsxr 1000 engine after he got it bored out and I couldn't believe how little and light it was.  He had it sitting in the backseat of his truck.  I sure as hell wouldnt want the F2 engine sitting on my back seat!  What are you thinking of doing xune?   :confused:


Shep: I was wondering what happ'd to your forks.  You'd never said anything more about them.  Do you already have the RGV250 forks?  Hope you do get to take more pics/video too.  Looking forward to that.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: steezin_and_wheezin on January 18, 2012, 07:48:20 PM
awesome progress. i don't post in here much cause i feel Way out of my league haha. this is one of the coolest/most dedicated projects i've followed since getting into the gs'

that snowmobile lights looks gnarly! should look pretty damn cool. you going to put some plastic around it?

Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on January 18, 2012, 08:16:42 PM
Shep: I was wondering what happ'd to your forks.  You'd never said anything more about them.  Do you already have the RGV250 forks?  Hope you do get to take more pics/video too.  Looking forward to that.
Nah, I just stumped on some guy's post about selling ones (here in Croatia, 200-300 kms from me), so I checked 'em on the net just to see what would that be like.
As I see it, they're too short, so I won't bother buying them.
I'm sure Tesla could make some extensions to make them fit, but to be honest... I'll rather wait for some user friendlier type o' forks.


Oh yeah, I almost forgot... one of these days I'm gonna take the bike to dyno-test, so I'll post the results here, of course.  :icon_mrgreen:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: xunedeinx on January 19, 2012, 06:46:00 AM
xune, you have to go answer the 'what the shaZam does your username mean' thread first. 

And my GS motor is just a basket case o' parts.  I can say that the F2 engine is obnoxiously wide.  I like it though.  I'd seriously do a FI engine swap before I did another one like this.  The 1000 engines are tiny compared to the F2 boat anchor.  A guy I know let me manhandle his gsxr 1000 engine after he got it bored out and I couldn't believe how little and light it was.  He had it sitting in the backseat of his truck.  I sure as hell wouldnt want the F2 engine sitting on my back seat!  What are you thinking of doing xune?   :confused:


My name, means nothing, Made it up in 6th grade bc it was cool and nobody knew what it was! Mysteriousness, ftw. Name sjust stuck, dont want to think of another.

Thinking of buying a track bike, or totaled one, once I get a car, and shoehorning it into my gs frame.

IDK if a GS1k would be a good idea or not, but a gs0.6k sounds sweet.

Was also thinking about a triumph triple, there seem to be a lot of them totaled around here...

Shep: I was wondering what happ'd to your forks.  You'd never said anything more about them.  Do you already have the RGV250 forks?  Hope you do get to take more pics/video too.  Looking forward to that.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on January 21, 2012, 03:15:56 AM
Tonite, worked somemore on my tank.  Ground down my welds and redid a few spots.  Tomorrow I hope I can finish the tank and get on with it.  Also mocked up my headlight!  I think it looks great!  Ok it looks really odd, but I think I'm going to go with it for now.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: xunedeinx on January 21, 2012, 07:50:14 PM
If its running under its own power, screw how the headlight looks, and enjoy it!
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on January 22, 2012, 03:02:52 PM
Yesterday worked on tank all day.  Today trying to finish it up, only the right side to go and test for leaks.   :2guns: 
@xune: I'm thinking the same thing.  Get it going and road legal, then go back to cosmetics.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on January 22, 2012, 05:10:27 PM
Just to drop by with a minor mod...
Replaced front brake hoses with steel braided ones.
Almost crashed on first test ride. Got to some 100-110 kph and applied front brake with the same force as usual (two fingers), front wheel blocked, slid to right hand side... Phew... Nice. Gotta be careful.

 :icon_mrgreen:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on January 23, 2012, 03:58:49 PM
Wow, that big of a difference eh?  Interesting stuff!  I'm glad you didn't wreck!  Need pics!  heheh

I ran out of material yesterday but almost finished my tank.  Ground down my welds and going to get somemore asap to finish it off.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on January 23, 2012, 05:40:03 PM
Pics tomorrow, right now, I'm trying to get real cbr tacho inside the housing.
Got it for free (minus the needle), and I want the rpm reading to be acurate, cause that chinese eBay junk proved to be total, way too expensive crap.
 >:(
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on January 24, 2012, 02:46:13 AM
(http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash4/403113_3160799422192_1331504559_3289289_699975932_n.jpg)
Cleaned up my grinding mess and then started looking at what to do.  Still didn't get my stick to finish up welding the tank so made some brackets to start on my headlight.  Gauge pod is just sitting on top of it.  Might need to angle light down somewhat to make it look right.  I wanted something extra wide and big.  Thinking of fabbing up some shield, shroud, something to tie it together.  Why do I keep thinking of a shovel blade?  Still have a nice giant fender to fit on there too eventually.  Hung the sheet to be able to see it without all the camouflage clutter behind it.
(http://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash4/399937_3160868183911_1331504559_3289302_219154991_n.jpg)
one more,....
(http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash4/s720x720/406564_3163722415265_1331504559_3290200_171601184_n.jpg)
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on January 24, 2012, 03:19:51 PM
As promised... the latest pictures of my bike (just a few, cuz it's starting to rain):

First... what I've been doin' last night:
(http://img33.imageshack.us/img33/4513/imag0202gb.th.jpg) (http://imageshack.us/photo/my-images/33/imag0202gb.jpg/)

Dual calipers detail (well, not so detailed):
(http://img546.imageshack.us/img546/4448/imag0203tr.th.jpg) (http://imageshack.us/photo/my-images/546/imag0203tr.jpg/)

Then, front look... just to show brand new steel braided lines:
(http://img850.imageshack.us/img850/2854/imag0204p.th.jpg) (http://imageshack.us/photo/my-images/850/imag0204p.jpg/)

And finally, left side view of the whole package (never mind the rusty fence on the back):
(http://img525.imageshack.us/img525/9484/imag0206pc.th.jpg) (http://imageshack.us/photo/my-images/525/imag0206pc.jpg/)

Btw, yes, that's a new gas tank, since my old one was rusty, and starting to leak.
That red strip was Tesla's idea, and I like it, cuz it gives some width to the bike, it looks bulkier than it actualy is.
Of course, you have to look at it at a certain angle (this is not the one :icon_mrgreen:) to get the picture.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Phil B on January 24, 2012, 03:53:56 PM
You shoulda changed the tail markings to read, "GS600" ;)
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on January 24, 2012, 03:54:16 PM
Looking goooood Shep.  I don't see the temp gauge you were talking about.  Did you drop that idea?  Do you ever get asked about it with confused looks?  Really looks nice.  It makes my day, everytime I see it.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on January 24, 2012, 03:58:52 PM
Looking goooood Shep.  I don't see the temp gauge you were talking about.  Did you drop that idea?  Do you ever get asked about it with confused looks?  Really looks nice.  It makes my day, everytime I see it.
The temp gauge is inside the tacho housing, you can see it almost covering the number 3 on the scale (and the needle is shortened, so it doesn't get in swordfight with tacho needle).  :icon_mrgreen:
Well... the people who know GS' notice the difference straight away, and the others think it's just another inline four.

You shoulda changed the tail markings to read, "GS600" ;)

This way it's more interesting when some squid launches off traffic light, just to be surprised I'm right next to him.
Hm, that would make me a squid too?  :cookoo:
 :icon_mrgreen:

Anyway, the tail should be repainted one of these days, so I'll figure some new style markings, to be in sync with tank.  :thumb:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Phil B on January 24, 2012, 06:35:46 PM
This way it's more interesting when some squid launches off traffic light, just to be surprised I'm right next to him.
Hm, that would make me a squid too?  :cookoo:
 :icon_mrgreen:

Anyway, the tail should be repainted one of these days, so I'll figure some new style markings, to be in sync with tank.  :thumb:


Go for maximum confusion: label it a "GSY 600":  a GSX with a part or two missing :D
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on January 28, 2012, 02:55:41 AM
http://youtu.be/prCVg7itdpc

Posted this on redge's muffler thread too.  Been procrastinating doing the video since my fuel delivery problem has been ongoing.  Tonight I finally got all the pinholes welded up in my tank and called it a day.  Massive frustration working on my tank as I couldn't get the bung welded in and had to cut it out and rethink how to do it.  Ended up using a bolt, welded it to a small piece of steel, then drilled through the shank.  Common hose fitting screws on to the threaded side and I ground off the inner top part of the bolt even.  Welded the whole thing in place of first bung and turned out ok.  pita to say the least.
After that, did quick video.  I hadn't run the bike in about two weeks, maybe longer so it puttered more than usual on start up.  Then cleaned up and called it a day.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: xunedeinx on January 28, 2012, 07:16:20 AM
http://youtu.be/prCVg7itdpc

Posted this on redge's muffler thread too.  Been procrastinating doing the video since my fuel delivery problem has been ongoing.  Tonight I finally got all the pinholes welded up in my tank and called it a day.  Massive frustration working on my tank as I couldn't get the bung welded in and had to cut it out and rethink how to do it.  Ended up using a bolt, welded it to a small piece of steel, then drilled through the shank.  Common hose fitting screws on to the threaded side and I ground off the inner top part of the bolt even.  Welded the whole thing in place of first bung and turned out ok.  pita to say the least.
After that, did quick video.  I hadn't run the bike in about two weeks, maybe longer so it puttered more than usual on start up.  Then cleaned up and called it a day.

When the time comes to shoehorn some off the wall motor into my gs's carcass I'm making you come on a trip to Florida.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on January 30, 2012, 04:16:30 AM
Sweeee-eeet Florida is the bike capital of the US right???!  Rockin!  But xune your GS is too nice to cut and paste an i4 into it!  Well at least until your twin can't take anymore.

Today messed around with the tank somemore and fiddled with gauges and how I want them to sit.  I want it to be something different up front.  That's why I chose that XL light.  Going to work on getting gauges set, then fab up something to tie it together.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: xunedeinx on January 30, 2012, 01:45:48 PM
Sweeee-eeet Florida is the bike capital of the US right???!  Rockin!  But xune your GS is too nice to cut and paste an i4 into it!  Well at least until your twin can't take anymore.

Today messed around with the tank somemore and fiddled with gauges and how I want them to sit.  I want it to be something different up front.  That's why I chose that XL light.  Going to work on getting gauges set, then fab up something to tie it together.

Yea, I think it is.

Post up some pics, and I'll give you my 2 cents if its wanted! Extra points for videos.

I'm thinking about buying a cheap totaled 600 bandit, and using that. I can make the rear swinger work, the i4 isn't too powerful, and I would wind up using its whole engine harness and making it work.

I'm a god with a solder iron and too much time.

Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on January 30, 2012, 02:49:28 PM
I'm thinking about buying a cheap totaled 600 bandit, and using that. I can make the rear swinger work, the i4 isn't too powerful, and I would wind up using its whole engine harness and making it work.

I'm a god with a solder iron and too much time.
My 2 cents: Suzuki oil/air cooled (Bandit, Katana and similar i4's) engines are waaaay too big for GS frame (no way to put them in, at least  not without cutting the whole frame to pieces).
I've checked that before finding out cbrfxr67's project as a guide line.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: xunedeinx on January 30, 2012, 02:53:24 PM
I'm thinking about buying a cheap totaled 600 bandit, and using that. I can make the rear swinger work, the i4 isn't too powerful, and I would wind up using its whole engine harness and making it work.

I'm a god with a solder iron and too much time.
My 2 cents: Suzuki oil/air cooled (Bandit, Katana and similar i4's) engines are waaaay too big for GS frame (no way to put them in, at least without cutting the whole frame to pieces).
I've checked that before finding out cbrfxr67 project as a guide line.

Oh, good info!

Is the 600cbr the only that will fit, or are there other small sized i4 600's?

How about the speed triple in the triumph?
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on January 30, 2012, 03:05:08 PM
I still vote GSXR1000 fi.  Tiny little engine with big power!
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: xunedeinx on January 30, 2012, 03:08:14 PM
I still vote GSXR1000 fi.  Tiny little engine with big power!

Eh, I only want enough powah to do 2 up with my wife comfortably. Its more the torque than the HP, honestly.

If a FI triple could fit, I'd be heaven.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: xunedeinx on January 30, 2012, 03:23:56 PM
BTW, dimensions of my friends tripumh triple 955i are, in inches:

15w (from side to side, 12l (from front to back), and 16h (from bottom to top.

Measurements are approximate cause the fairings are still on, but its info none the less.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on January 31, 2012, 03:04:36 AM
Make some new brackets, weld them on or bolt in where they'll fit right and G-O!  I wonder how much a 955i engine is going for on cl or ebay,.....hmmmm,...
Tonight worked on gauge bracket.  Was a little tired from work and neighbor wanted me to help him with his F150 coils, so didn't get as much done as I wanted. :technical:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on February 02, 2012, 03:53:58 PM
Last night made a bracket on the tail and mounted my little vacuum operated fuel pump.  Ran my copper line down the tail to vacuum assist on number one and connected in my manual shut off.  Messed around with tank locating and called it a day.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on February 06, 2012, 04:34:32 PM
Funny how the more you do, the less feeling of accomplishment you get.  Worked on brackets for gauge pod and finished that; nice and solid.  Worked more on the pita tank, getting mounting points to frame done.  That was it.  Feels like I didn't do squat yesterday.  A year ago I probably would have felt great like I'd really done something.  Now I just feel like I need to hurry up already.
 >:(
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: xunedeinx on February 06, 2012, 07:56:34 PM
Funny how the more you do, the less feeling of accomplishment you get.  Worked on brackets for gauge pod and finished that; nice and solid.  Worked more on the pita tank, getting mounting points to frame done.  That was it.  Feels like I didn't do squat yesterday.  A year ago I probably would have felt great like I'd really done something.  Now I just feel like I need to hurry up already.
 >:(

If you dont want it, drop it off in my living room!
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: xunedeinx on February 09, 2012, 03:21:57 PM
I have an idea....

I been looking at customfighters.com, and saw a pic of a katana naked...

If I got an old katana 750 for dirt cheap, I can gut it, strip out the wireing harness etc.. and, for the most part, the frame is similar to the gs500.

Now, if I get a non-title able gs frame, chop off the hear subframe, and slap it on the katana, and add on a round frong headlight...

Its be a gs500, with a katana engine, and all the mods pre done!

Seems like all the mods we do are - gsx600 shock, front forks, rear wheel, dual brakes....

Am I on to something here? =)
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: xunedeinx on February 09, 2012, 03:24:31 PM
(http://storage1.colony1.net/2195/Product_Photos/get%20home%20002.jpg)
(http://imagehost.vendio.com/a/35081140/aview/_BiY_6cQ_Wk___KGrHqEH_CkEsLWoOi3GBLOqZ_GJ5Q___1.JPG)

(http://imagehost.vendio.com/a/35010510/aview/265718584_tp.jpg)
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Phil B on February 09, 2012, 05:41:42 PM
...
If I got an old katana 750 for dirt cheap, I can gut it, strip out the wireing harness etc.. and, for the most part, the frame is similar to the gs500.
Now, if I get a non-title able gs frame, chop off the hear subframe, and slap it on the katana, and add on a round frong headlight...
Its be a gs500, with a katana engine, and all the mods pre done!

Umm... sounds like you could save yourself even more hassle, if you just bought a katana, took off any fairings, and bolted on a gs500 headlight somehow.
There, done?   :D
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: xunedeinx on February 09, 2012, 07:17:33 PM
But, the katana rear subframe and tail section is U-G-L-Y!!

Katana + gs500 rear + headlight = gs500 with i4!

Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Phil B on February 11, 2012, 05:28:39 AM
Now yer talking!

So... dont keep us waiting too long with your pictures of that project ;)
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on February 12, 2012, 03:53:50 PM
Xune where's the build thread??  I keep looking but I'm missing- oh there it is,....just posted on your gsxf600 thread!  Rockin!!

Yesterday finished mounting tank to frame.  Used some new bits from Astro that are drill bits on the end but morph into taps midway through.  Drill and tap at once and makes sure you use the right sized bit for the screw size.  (Astro Pneumatic #9452)  So, got tank set up and ran it for a short while.  Smoking electrical tape close to rectifier caught my attention plus it seemed to be backfiring a bit.  I keep a rectifier on the shelf, just in case, so grabbed it and swapped out my old one.  The resin had cracked years ago on the old one, but never gave me trouble til now.  With the new one on there, sounded clean and crisp again.  Revved a little bit then shut it off. 

Added some 'easy charge' cables to battery posts since it is too far up under tank to clip on the clamps.  Also completely hacked my old GS tank.  Cut out a huge section of it to be able to turn it into a 'cover.'  I forsee going back and trying to make a new tank eventually with bigger capacity.  If anything, I've learned alot recently in building this first tank.

Today, going to work on wiring up front and start tucking it in.  I want to get some loom to tidy it up, down the side.  I don't want to nip and tuck it and then have problems and have to take all that shaZam apart again.  I'd rather use some loom and put the extra behind the headlight.
Also, want to work on tank 'cover' and set the tail up.  Tail needs gorilla glue repairs, then can start cleaning it up.  Really want to put my fender on there.  Might sand it down and get to repairing it.  I typically only buy cracked bodywork, fix it and respray it.  Fender has a fat crack down the backside but mounting holes are good.  Thinking of a hugger too, I seem to recall one of the members selling a hot little one.  Need to look that up.  Ok time to get to work,.....


Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Funderb on February 14, 2012, 02:27:12 AM
@OP

I see you are in the...

"WTF! I just want all this nitpicky stuff to be done why is it taking so long, the bulk work was so fast and easssyyy!"

... stage of custom building something.

I know exactly, the feeling. I cant wait to see this thing running the roads.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on February 14, 2012, 03:45:32 PM
Funder,..exactly right.  I didn't get crap done the other day.  Got plenty of frustrated though.  Worked on wiring up front and seemed like more I was doing, the less was getting done.  How does that work?  Ended up throwing in the towel after an hour or so.  My wise boss (older gearhead) once told me: 'Put your stuff up and come back to it.  Things that were baffling you before will work out and you'll be wondering why you were having such a hard time previously.'
Basically took headlight off, Rapidfixed (this is a great product if you've never tried it) a crack in the back of it, learned I needed a bulb, cut down and shaped the bracket better,  & ziptied wiring and stuffed it under the gauge pod, oh and frustrating part was tank still giving me a headache (mounting).  Ordered a bulb and some wire loom, so waiting for it to get here.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on February 15, 2012, 02:22:01 AM
Tonight was having fun.  Mosquitos were out in force so started it up and filled up the garage with fumes.  Mosquitos hate exhaust. 
Wired in my tail light and got happy with the bright led glow.  It is integrated but I haven't decided if I want to use it that way or not.

(http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc7/429587_3341447498281_1331504559_3356714_466160759_n.jpg)

Then played around with my gigantic fender.  I like big fenders.  Had to trim the far side to clear the caliper.  I'll have to do some creative work to use this as there is nothing to mount from.  You can see the grand canyon crack in it.

(http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc7/427136_3341448098296_1331504559_3356715_242767957_n.jpg)

Last tossed on broke, misaligned and scarred pieces to see how the 'outline' was shaping up.  Yes it looks terrible but I see where it is going and am happy with how the lines are coming together slowly.

(http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash4/417474_3341448538307_1331504559_3356716_1224654740_n.jpg)
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: codajastal on February 15, 2012, 02:41:27 AM
WTF? Is that tank weird looking or is it just me? ;)
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: xunedeinx on February 15, 2012, 06:47:02 PM
(http://img.photobucket.com/albums/v636/xunedeinx/0215121336.jpg)


Ohhhhhh YEAH!
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on February 20, 2012, 01:03:39 AM
xune that looks fzantastic!  Love the tip!

Today, worked on the 'cover' for the tank.  I forgot how hard it is to weld on ultra thin metal.  Finally started getting the hang of it again after multiple blow throughs and spitting and sputtering.  Seems like you could easily stab a screwdriver through the metal that the tank is made out of.  Maybe it just seems that way and really it is fine.  So, that's all I did today.  My son expressed how ugly my tank creation was after I posted the pic the other day, but I told him it isn't finished yet.  The 'cover' will conceal that monstrosity.  Would've taken pics but my phone battery died out.  I'd like to document how it comes together since right now it is fuuuu-uuuhgly.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on February 20, 2012, 02:16:27 PM
I'm applauding you for the effort and persistence you're showing with the tank mod, but once again, I'm suggesting the much more easier way (and preserving the full GS tank capacity), by creating custom stainless steel air intake system.
At least it's easier to weld 2mm thick stainless steel plate than hair thin tank material.
 :icon_mrgreen:

Btw, I had to modify that K&N drop in filter, because of the CBR engine's thirst for air (only downside of not using cbr's airbox).
With K&N I've experienced a bit of pull hesitation near 10k rpms, so I had to grind K&N's intake port to a maximum possible opening, now the engine's hitting redline at 13-14k with no problem (tested in third gear).
Finally I'm satisfied with filtered air supply (ever since completion of project, I've been ridin filterless :icon_mrgreen:, because of choking symptoms due to Gs' low airbox volume), so my fear was the cylinders will get grinded by sand, dust or something else sucked in while riding.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on February 20, 2012, 03:00:26 PM
Thanks Shepa, but I must applaud you for actually finishing this and been riding for a year now!   :bowdown:

I'm getting there.  Fortunately I have my other F2/3 to ride and am not hurting for a bike.  I'm pretty sure that is the only reason I am not sweating the delay.  Otherwise I'd be Tombstone aggravated and do it your way (the way that works).  It is a challenge for me to get this right and have it come together.  Although a pita, if I can do it, I'll really feel like I did something neat.  If I fail then I'll try something else.

Oh Shep, you forgot to add a pic with your last post.  :thumb:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on February 20, 2012, 03:42:58 PM
Oh Shep, you forgot to add a pic with your last post.  :thumb:
Oooops! You're absolutely right! :icon_mrgreen:
Here you can see that I grinded the K&N intake port almost completely to the wiring.

(http://img842.imageshack.us/img842/4821/imag0241e.jpg) (http://imageshack.us/photo/my-images/842/imag0241e.jpg/)
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on February 23, 2012, 01:10:07 AM
Shepa rockin' the pics,..

Yesterday spent chasing electrical problem.  No headlight.  Turn signals and horn work fine, but no power to headlight so got out meter and started checking everything.  Traced up to the low/high switch but not sure if that is it.  I have power up to that and nothing at the switch or, of course to the light.  Will mess with it more later. 

Today rode my 600 and f-r stalled on me.  Pulled out of traffic, because I had a hunch it was going retarded, into a big church parking lot and it crapped out.  Let it sit for about ten minutes, cranked it and it started fine, burbled some but didn't stall.  Got home, and let it sit there idling, waiting for it to stall and of course it didn't.  Stupid carbs.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on February 26, 2012, 03:03:04 PM
Worked out my electrical issue yesterday.  Had power through the harness to the horn and to the turn signals but not to the headlight.  Power to the switch made the light work, but it wouldn't work through the harness.  Anyways, went in & rewired the headlight to the switch and works fine now.  Pic is me testing what works vs what doesn't. 

(http://sphotos.xx.fbcdn.net/hphotos-ash4/407527_3425322115094_1331504559_3390656_979417796_n.jpg)

After that, took it out and rode around.  After warm up (valves soon) it ran like a champ.  It was the first time I really hammered it up and down the street.  Position felt tighter and much more centered than on my F2.  Needless to say it was really fun.  Today, sewing up wiring and more cosmetic work.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: xunedeinx on February 26, 2012, 08:58:33 PM
Picture of the video w/ the gas tank cover and video of it running + revs all ready!!!!!
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on February 27, 2012, 03:09:54 PM
Xune videos only in victory,....I'm still far from it.  Speaking of that, check out the 'before and after' thread.  I updated the F3 with a pic of it after the guy wrecked it.  doh!

(http://sphotos.xx.fbcdn.net/hphotos-snc7/428177_3431682914110_1331504559_3395193_491141317_n.jpg)

Put my giant light back on and taped up connections yesterday.  Went back to work on tank cover,....
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: xunedeinx on February 27, 2012, 03:21:03 PM
Xune videos only in victory,....I'm still far from it.  Speaking of that, check out the 'before and after' thread.  I updated the F3 with a pic of it after the guy wrecked it.  doh!

(http://sphotos.xx.fbcdn.net/hphotos-snc7/428177_3431682914110_1331504559_3395193_491141317_n.jpg)

Put my giant light back on and taped up connections yesterday.  Went back to work on tank cover,....

Ill GIVE you my fairings + stay and stuff if you pay shipping, just cause that headlight looks awful (in my eyes)

Shipping may be around 40-60 bucks, but itll include all mounts and fairing stay and headlight.

Offers out there for ya brother.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on February 27, 2012, 06:14:33 PM
Thanks xune.  DON'T think I didn't want to buy them from you when I saw your For Sale thread awhile back.  If this front end, tank, tail configuration come out looking whack and if you still have them, I'll sure take you up on it.  I just want to try this and see how it comes out first.  :icon_mrgreen:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: xunedeinx on February 27, 2012, 06:23:23 PM
Thanks xune.  DON'T think I didn't want to buy them from you when I saw your For Sale thread awhile back.  If this front end, tank, tail configuration come out looking whack and if you still have them, I'll sure take you up on it.  I just want to try this and see how it comes out first.  :icon_mrgreen:

I'm willing to support a person with plastic I dont need in order to achieve the ultimate goal of awesomeness!
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: mysterious_rider on February 29, 2012, 05:07:47 PM
Interesting project, but im really not a fan of that snowmobile light and that tank.  :icon_lol:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Tombstones81 on February 29, 2012, 05:13:22 PM
Nice build!
been watchin but a lil too much for my knowledge atm to Fully appreciate in the mechanical sense.

Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on February 29, 2012, 06:13:10 PM
xune convinced me to try fiberglass on the tank cover.  Was trying to keep on with my tank welding plan but just isn't working, so going to try some fiberglass and see how it comes out.  Thanks for the comments mysterious.  Opinions welcome! 

Thanks Tomb.  Not sure what you're talking about though, cause you've had your engine opened and closed more than,....(insert YMHK worthy joke here).  That definitely takes 'know how.'
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Tombstones81 on February 29, 2012, 06:35:30 PM
xune convinced me to try fiberglass on the tank cover.  Was trying to keep on with my tank welding plan but just isn't working, so going to try some fiberglass and see how it comes out.  Thanks for the comments mysterious.  Opinions welcome! 

Thanks Tomb.  Not sure what you're talking about though, cause you've had your engine opened and closed more than,....(insert YMHK worthy joke here).  That definitely takes 'know how.'

hahaha but thats totally different then all the welding and fitting a bigger different engine into the GS frame.

i've never cut and welded anything before.
so all the work to make things fit etc etc is nice but I cant fully understand it yet to fully appreciate it.
aka like oh yeah I know how to do that and understand it completely, pretty cool etc etc
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: xunedeinx on March 01, 2012, 03:54:52 PM
xune convinced me to try fiberglass on the tank cover.  Was trying to keep on with my tank welding plan but just isn't working, so going to try some fiberglass and see how it comes out.  Thanks for the comments mysterious.  Opinions welcome! 

Thanks Tomb.  Not sure what you're talking about though, cause you've had your engine opened and closed more than,....(insert YMHK worthy joke here).  That definitely takes 'know how.'

Its easier than welding, thats for sure!

You make a mistake, cut it off, and throw on a new peice of glass.

Hardest challenge will be symmetry.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on March 05, 2012, 04:41:25 PM
So, scraped up 200 big ones, went and picked up a 2001 Fireblade 929 over the weekend.  I really went for the engine and everything to get it running but guy was moving and let me take the whole thing.  Also, threw in a cbr 900rr rolling chassis with the engine in a basket case (another one?).  I couldn't pass it up when he was bringing out more and more stuff for me to take.

First look with borescope, things look good.  Too much crap is disconnected to see if it'll fire up and this is my first journey into FI territory, so need to get more informed.

Too bad I didn't find this sooner and could've put the 929 in the GS. (sweet)

(http://sphotos.xx.fbcdn.net/hphotos-snc7/430495_3478126115161_1331504559_3416066_532970588_n.jpg)

Worked on my tank cover over the weekend.  Fiberglass is actually kind of fun to work with.  Smells to hell though.  That was about all I got done.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: xunedeinx on March 05, 2012, 06:21:35 PM
Wish I had that kinda of luck.

I can make one hell of a bike out of those two hondas!
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on March 05, 2012, 06:58:55 PM
...
Too bad I didn't find this sooner and could've put the 929 in the GS. (sweet)
I hate you...  :icon_twisted:





 :icon_mrgreen:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on March 08, 2012, 03:17:31 AM
Got the 929 started tonight.  Rounded up some used spark plugs, wire brushed them shiny and made sure gap was ok.   Finally found all the coils in the mountain of parts and got them connected.  Hooked up the jump box and it fired right up.

(http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc7/423692_3494582086550_1331504559_3422083_1727173000_n.jpg)

I didn't run it but for a moment cause I didn't have everything connected and haven't really gone over the bike much.  Just wanted to see if it would fire.  Still gave me that good feeling to hear the engine start!
(http://i476.photobucket.com/albums/rr125/littleotteratplay/animi/th_jig.gif)
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Tombstones81 on March 08, 2012, 03:34:03 AM
 :icon_eek:
Very lucky and well deserved!!  :thumb:  :thumb:  :thumb:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: knowles on March 08, 2012, 04:42:52 AM
Wish I had that kinda of luck.

I can make one hell of a bike out of those two hondas!

Me too, i can never find anything like that. I would try a off road go cart with the honda motor. it would be sweet.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: steezin_and_wheezin on March 08, 2012, 04:48:25 PM
Jealous cbr!! congrats on the parts bike gold pile!

My room mate would kill for that 929 parts bike, that was his ride back when he was on sports bikes.

Side note, when ya getting a better camera?? :icon_mrgreen:

Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on March 09, 2012, 03:45:14 PM
Thanks,....I really try to stay off CL because I end up wanting to go pick up more and more.  Just happened to find this one when my f2 pissed me off the other day stalling out and I searched for some fi.

Been working on the GS tank cover more and more.  I'm a novice to fiberglass but it is fun.  Kind of like sculpting I guess.  Like xune said, 'make a mistake, cut it off, and throw on a new peice of glass.' 
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on March 12, 2012, 06:01:11 PM
(http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash4/427718_3523947380664_1331504559_3434778_812045893_n.jpg)

Really had a fun time as it was the first time my son got to come work on the GS with me and spend the weekend.  He made a bracket for the tail light and place for the tail seat cover to clip to.  While he was doing that I worked on cover and body work.  Also dismantled the 929,....

(http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash4/425642_3523946620645_1331504559_3434776_849886411_n.jpg)

(http://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc7/423335_3524007222160_1331504559_3434811_926753497_n.jpg)
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: xunedeinx on March 12, 2012, 06:41:23 PM
That engine is sexy, and should be in my frame...
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on March 13, 2012, 05:06:37 PM
That engine is sexy, and should be in my frame...
My thoughts exactly...  :icon_mrgreen: :icon_mrgreen: :icon_mrgreen:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: xunedeinx on March 14, 2012, 12:54:38 AM
That engine is sexy, and should be in my frame...
My thoughts exactly...  :icon_mrgreen: :icon_mrgreen: :icon_mrgreen:

Heres the deal, I'll drive up there, we'll spend a weekend getting it 99%, I'll limp it home, and finish it up.

Deal?

Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on March 18, 2012, 03:06:54 PM
Was NOT a good day yesterday working on GS.  Wouldn't fire up.  I mean, just refused.  Then bad fuel leak started and I was feeling the tomb rage approaching.  >:( Yanked off that jacka** tank and pulled the fuel lines and considering something else now.  I'm sure Shep will have a few words for my stubborness. 

On the other hand, body work is going very nicely.  Rapidfix is the shaZam for fixing abs!  Easy to use and crazy strength in no time.  Did my grand canyon sized cracked fender and the hacked 600rr tail.
(http://lh3.googleusercontent.com/public/uzPKhpdw994HYxuX-4Rr8SiTo4mqZIkSDBnpPMTibqx6-oKKmuhJJUpzf9TnYtzr3-PyGr6NzHxafoBA4dlmbBRKgS0DdkSD9-28BWhH9rWQv_AwjAgyAmph1kVPEmylL82IdT2XRCi8jJnBmWLWF4U3h_abReRaMJ-v9YFiWFoBiR8Z1Agd1Klb9g-2AIEP99N5UVp71PSNGqmXfDrumtPpOK1Fd6rxNatTOr35gTnUuGXbDQ3mzBl90RDm9faWFeN96FXF6c8CzjrjiU9n1jfhu__XzdXohMDUj65VT9edSrnf7uQ3)

Bought a motion pro carb sync tool last night after watching youtube video on it.  I have vacuum gauges style manometer but want to try the 'mercury' style and see if it is easier to use.
http://youtu.be/2nwP6R1P58A
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on March 19, 2012, 02:10:14 PM
Not much to report.  Doing bodywork,...sanding, priming, Rapidfixing, minor fiberglassing,...etc.
(http://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash4/405158_3569444438062_1331504559_3454555_1491478687_n.jpg)
Did start rolling out some cardboard to get an idea of a shroud around my (gigantic) headlight.  Much props to xune for telling me about fiberglass and how easy it is to use.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: dropitlow88 on March 20, 2012, 01:31:16 AM
Not much to report.  Doing bodywork,...sanding, priming, Rapidfixing, minor fiberglassing,...etc.
(http://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash4/405158_3569444438062_1331504559_3454555_1491478687_n.jpg)
Did start rolling out some cardboard to get an idea of a shroud around my (gigantic) headlight.  Much props to xune for telling me about fiberglass and how easy it is to use.
i read this entire thread last night and i am determined that within a year i will start a similar build (next tax season lol) lovin it. great job, and that deathray of a headlight reminds me of the huge wraparound sunglasses old people wear :thumb: props to you for the creativity and back yard mechanic ingenuity. I'd love to come over there and turn a wrench with ya for the weekend.  :cheers:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on March 20, 2012, 02:57:07 AM
"that deathray of a headlight reminds me of the huge wraparound sunglasses old people wear" (quote dropit)
(http://www.motohouston.com/forums/images/smilies/laughing6.gif)(http://www.motohouston.com/forums/images/smilies/laughing6.gif)(http://www.motohouston.com/forums/images/smilies/laughing6.gif)
that made my night, thanks dropit!  Too funny! 

So, kind of interesting that dropit (edit- sorry I meant bombsquad, my bad) is doing a tank restore and it gave me the idea of using my supertanker 900 tank on the GS.  My son loved it.  I kind of like it too.  With my deathray headlight and supertanker gas tank, gives it a real 'what the' appeal.  Have to fab up a base for it so it doesn't look retarded hanging out in space from the sides.  Opinions welcome,....?

(http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash4/431794_3572739640440_1331504559_3455994_837371094_n.jpg)
Will have to do something like dropit (edit-bombsquad, doh!) is doing on his tank to get the crap and gunk out of it.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: dropitlow88 on March 20, 2012, 03:15:17 AM
"that deathray of a headlight reminds me of the huge wraparound sunglasses old people wear" (quote dropit)
(http://www.motohouston.com/forums/images/smilies/laughing6.gif)(http://www.motohouston.com/forums/images/smilies/laughing6.gif)(http://www.motohouston.com/forums/images/smilies/laughing6.gif)
that made my night, thanks dropit!  Too funny! 

So, kind of interesting that dropit is doing a tank restore and it gave me the idea of using my supertanker 900 tank on the GS.  My son loved it.  I kind of like it too.  With my deathray headlight and supertanker gas tank, gives it a real 'what the' appeal.  Have to fab up a base for it so it doesn't look retarded hanging out in space from the sides.  Opinions welcome,....?

(http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash4/431794_3572739640440_1331504559_3455994_837371094_n.jpg)
Will have to do something like dropit is doing on his tank to get the crap and gunk out of it.
that thing looks good. not bad at all. little tall, but, what the hell... it's not like it was made for it or anything :cool: go for it. have you looked into side draft carbs like the gs? i think that would give u much more room to fabricate a filtration system for it. those down draft jobbers just eat up way to much space on the gs. to me it would be worth it to fab up a new induction system for that simple reason. gas is the oxygen, oil is the life blood. with a 70 mile range it think i'd get tired of visiting the gas station. although the new tank does some justice with extra volume. just something to think about. great job thus far, thing is awesome :thumb:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: ben2go on March 20, 2012, 04:29:49 AM
What tank is that?It may be worth a shot instead of trying to make two tanks meld into one.

(http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash4/431794_3572739640440_1331504559_3455994_837371094_n.jpg)
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on March 22, 2012, 02:05:30 AM
Started my electrolytic rust remover on the tank tonight.  Was going to use some acid or try something like that but wanted to go with the electrode and see what happened.  Ok it looked more interesting, I admit it.
 
Did some more sanding on body work and made a template to start my 'base' for the supertank.

Was thinking how I originally wanted this to come out like Shep did his and now it has turned into a full fledged 'what the' build,....oh well, having fun with it.

Oh and Ben2, tank came off the 900 I scored a couple weeks back.  I think I'll give it a shot and see what happens.  If anything, it is better than the 'cover' I was working on with my homebrewed weld-a-tank.  But that was fun too, so I'm not too disappointed.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: ben2go on March 22, 2012, 03:06:00 AM
Started my electrolytic rust remover on the tank tonight.  Was going to use some acid or try something like that but wanted to go with the electrode and see what happened.  Ok it looked more interesting, I admit it.
 
Did some more sanding on body work and made a template to start my 'base' for the supertank.

Was thinking how I originally wanted this to come out like Shep did his and now it has turned into a full fledged 'what the' build,....oh well, having fun with it.

Oh and Ben2, tank came off the 900 I scored a couple weeks back.  I think I'll give it a shot and see what happens.  If anything, it is better than the 'cover' I was working on with my homebrewed weld-a-tank.  But that was fun too, so I'm not too disappointed.

Thanks for the info.I'm about a year out from tackling the super tank for my project bike.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on March 23, 2012, 02:20:57 AM
(http://sphotos.xx.fbcdn.net/hphotos-ash3/544908_3593380716454_1331504559_3464649_767947905_n.jpg)

Checked my experiment today.  Looks like a cross between beef jerky and barnacles.  Scraped it off and put it back in.  This was a clean piece of steel when I started yesterday.  Tomorrow will change the water/soda solution out and let it go for another day.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Big Rich on March 23, 2012, 02:28:36 AM
Whoa! If you didn't say what that was, I probably never would have guessed.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Funderb on March 23, 2012, 04:12:32 AM
Dude! that is awesome!
I have been reading about electrolysis to derust a tank, and I'm totally going to use it on the fzr1k when i get the chance. Its supposed to strip out all the crappily adhered tank liner too. That is some crazy stuff. I've heard welding rods are also a good and easy to clean anode.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: dropitlow88 on March 23, 2012, 12:52:18 PM
Dude! that is awesome!
I have been reading about electrolysis to derust a tank, and I'm totally going to use it on the fzr1k when i get the chance. Its supposed to strip out all the crappily adhered tank liner too. That is some crazy stuff. I've heard welding rods are also a good and easy to clean anode.
idk about welding rods bc of the flux. I used a coat hanger on mine. Let it bake for three days. it does work well. biggest problem I'm having now is leaky pin holes 
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on March 24, 2012, 02:35:13 AM
(http://sphotos.xx.fbcdn.net/hphotos-ash4/399056_3599662473494_1331504559_3466997_1727516789_n.jpg)

Same again today.  Really looks like barnacles.  If only I had a S&W camera, you could see the little barnacle like formations on it.  Scraped it off and stuck it back in for the night.  Tomorrow will rinse tank with vinegar and see how it looks.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Funderb on March 24, 2012, 03:08:27 AM
Quote
idk about welding rods bc of the flux

Meh, maybe metal dowels then? CBRFXR, is that just a bit of sheet steel you are using, or bar stock?
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: dropitlow88 on March 24, 2012, 04:15:15 AM
Quote
idk about welding rods bc of the flux

Meh, maybe metal dowels then? CBRFXR, is that just a bit of sheet steel you are using, or bar stock?
either would work fine. all you need is a sacrificial conductor. as long as it conducts electricity it will work. i like coat hangers because they can be bent and maneuvered easily. but anything will do, bar stock, thread all, sheet steel, whatever you have laying around. just make sure the tank is well vented. the process has a byproduct of hydrogen  :icon_eek: 
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on March 24, 2012, 10:09:00 PM
Funder, it was actually an alternator bracket that was 3/16 maybe 1/4 thick. 

Today it looked the same again and I dumped the solution out.  Inside was better.  Strapped it to a couple of bungie cords and dumped a load of small nuts into it and every time I passed by I'd wind it up and let it go.  Did this for most of the morning while I was cleaning the porch.  Then rinsed it out and sprayed JB80 in it.  Boinged it around somemore for awhile and then got all the bolts out.  Rinsed again and more JB80.  Looked very good inside then.  I really recommend the electro method.  So easy and costs next to nothing.

(http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash3/551712_3604897804374_1331504559_3469551_807368229_n.jpg)
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: knowles on March 24, 2012, 10:31:40 PM
Holly shaZam! that turned out nice. Is there a wiki on this if not you should make one.

 :icon_mrgreen: :D :woohoo: :woohoo: :woohoo: :woohoo: :woohoo: :woohoo: :woohoo: :woohoo: :woohoo: :woohoo:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Funderb on March 25, 2012, 10:42:38 PM
haha, whatever you had sitting around. My kinda guy.

And yes, a step by step on wiki would be awesome.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Tombstones81 on March 26, 2012, 01:05:12 AM
^^ totally agree!
need some details!!

came out Great!
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on March 26, 2012, 04:08:30 PM
Wiki?  If only I'd taken more pictures maybe.  Steps were simpler than simple though:

Get tank. 
Get battery charger (if you have a 'smart' charger, use a battery too). 
Get 'electrode.' (Piece of steel that you can attach to wood block, across top of tank opening.)
Get 'Washing Soda" by Arm & Hammer. 
Get bucket. 
Mix about a cup of Soda with enough water to fill tank. 
Dump in. 
Use a good ventilated spot where tank and charger can sit for a few days. 
Secure wood block across the tank opening, with attached 'electrode' suspended in solution (NOT touching side of tank!).
Connect negative lead to tank. 
Connect positive lead to electrode.  (will start to fizz)
Come back next day.
Disconnect +/- and observe alien like rust formations on electrode.
Scrape off and reinsert into solution.  Top off if water level has gone down and reconnect leads (make sure electrode is not touching tank!)
Come back next day.
Disconnect +/- and observe more strange rust formations on electrode.
(repeat til happy)
Next I drained tank, poured a bag of 10mm nuts in, a little gas, and attached bungie cords on both ends, suspended between porch beam and the fence.  While doing other work, I would go by and twist it up, bounce it around for awhile.  Then used magnetic pick up to fish out nuts and rinsed.  Sprayed in JB80 and bounced it around somemore.  More JB80 and then I let it sit in the Texas sun all afternoon.

I was really happy with this.  Extremely easy.  Even Buddha could do it. :icon_razz:



Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on March 26, 2012, 04:13:32 PM
Yesterday worked on supertank set up.  Trying a few ideas for a base that would sit on the frame and the tank would rest on.  Have to come up with something, otherwise it looks ridiculous 'floating' over the frame.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: ben2go on March 27, 2012, 02:22:31 AM
Yesterday worked on supertank set up.  Trying a few ideas for a base that would sit on the frame and the tank would rest on.  Have to come up with something, otherwise it looks ridiculous 'floating' over the frame.

Any pics?
Title: Re: 1996 GS500 Basket Case Build into a 'what the',..
Post by: cbrfxr67 on March 27, 2012, 02:01:23 PM
Pics of failures, sure.  Tried some foam, was going to shape into what I needed then fiberglass over it, fail.  Styrofoam, tried yesterday,....fail again.  With Tomb rage :mad: approaching, I concentrated on making the bracket to hold the supertank since that was pretty straightforward.  Made a bushing and got the front set up and started on the backside and called it a day.
Thinking I will finish up the brackets then try another idea this evening.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: steezin_and_wheezin on March 27, 2012, 02:15:17 PM
damn, that tank came out great!! great work, and thanks for the quick write up. i will have to give it a shot on the crappy tanks i've accumulated.

failure or not, you know that photos make all the twinners happy!!
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on March 28, 2012, 01:48:27 AM
Especially when you take them with that amazing camera Steez!

Tonight worked on tank bracket.  Came out really stout, I was surprised.  Messed around with primed out fender.  Need to figure out how to mount it.  One side I can use a bolt location but the other side I'm going to have to figure something out.

Threw seat and tail on to see how it fit against the tank.  Seems A Ok. 

(http://sphotos.xx.fbcdn.net/hphotos-ash3/523932_3626243337999_1331504559_3479791_1488390183_n.jpg)

(http://sphotos.xx.fbcdn.net/hphotos-ash3/556244_3626255498303_1331504559_3479793_1307744515_n.jpg)

Need to get some supplies tomorrow so I can move ahead and start pulling all of it together.  For some reason I feel like I'm going to be finishing this sooner than later.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: steezin_and_wheezin on March 28, 2012, 01:21:45 PM
NICE! i thought those photos were on another bike, then i looked down at frame and swing.

that tank and seat look like they fit well in that photo! does it look that good from a step or two back?

Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on March 28, 2012, 02:31:12 PM
Looks ok.  Definitely need a bigger back tire eventually but not until I wear out the avon that is on there first.  Tank needs some trim for the gap.  That's what I've been working on (failing on) for the past few days.  I have a new idea I'm going to try this weekend. 

Starting to think about paint.  I've always wanted to do a black with a fade, rubbed through red on the curves.  Try to explain,....paint all the curves red, then all of it black, but sand/rub through the black, feather the curves to reveal the red.  I've always wanted to try that.  Definitely not a 'show' piece, more of the 'what the' theme.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: xunedeinx on March 28, 2012, 08:00:14 PM
Post pics and I may have an idea!
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on March 28, 2012, 08:26:46 PM
xune you are the originator of originality,....I KNOW you'd come up with something.  I'm going to try something this weekend.  If I fail on that, then I'll post pics and take you up on it sir.
 O0
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: xunedeinx on March 28, 2012, 10:34:42 PM
And...videos!!! :bowdown: :bowdown: :bowdown:
Title: Re: 1996 GS500 Basket Case Build into a what the,...
Post by: cbrfxr67 on April 01, 2012, 09:14:03 PM
Had a good day until headache started setting in,.....even Jehovah's witnesses came by to talk to me for awhile.

(http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash3/532733_3656243607987_1331504559_3493050_1750475935_n.jpg)

Yesterday I epoxied a small tab on the right front fork and zip tied it down so it could set overnight.  Today made a small attachment and set the right side.  Left side I used the bolt that holds the speedo cable bracket and made a one piece bracket.  Sorry forgot to get pic of that.  With those two mounts I think I'll shave the backside of the fender because the mount locations are unnecessary.

(http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash4/293876_3656243007972_1331504559_3493048_815490025_n.jpg)

(http://sphotos.xx.fbcdn.net/hphotos-snc7/394347_3656243447983_1331504559_3493049_233001606_n.jpg)

This was my latest idea (and beans & rice for lunch).  Expanding FOAM!  This stuff is awesome.  Pics are  first layer from yesterday, then I cut it down some.  Today reapplied and let it set up (says 8 hours to fully cure).  Next I'll shave it down, pull the tank off and lay fiberglass over it.  Then use some thinner to dissolve foam and build up fiberglass to the shape I need and finish it off.  Sounds easy in sentence form.  I hope it works.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: xunedeinx on April 01, 2012, 09:51:53 PM
THATS what I' :bowdown:m talking about!!
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on April 02, 2012, 07:37:44 PM
Hey dude... You're really making it big...  :icon_mrgreen:
I suppose you won't be needing any of those cbr forks?  :icon_idea: :icon_mrgreen:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on April 02, 2012, 07:48:18 PM
I thought about that Shep.  929 forks swap,.....   I don't know how hard that'd be though. 

How's your beast doing?  Need to do a good video of you cruising around.  I've never seen Croatia before, that'd be awesome!
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on April 03, 2012, 12:56:38 AM
Trimmed excess to get the beginning shape and then pulled the tank off.  Took these quick masterpiece shots,....(Steez point and laugh now).

(http://sphotos.xx.fbcdn.net/hphotos-ash3/532249_3663915079769_1323330599_n.jpg)

(http://sphotos.xx.fbcdn.net/hphotos-ash3/539918_3663914559756_1331504559_3497106_1147240268_n.jpg)

Then pulled off the tank, which looks like a mess, but that is before I trimmed it,......

(http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash3/522579_3663925200022_1331504559_3497111_1704732946_n.jpg)

Peeled it off carefully and set it up with a quick coat of resin.  That is all I got done tonight.  Tomorrow will lay on some mat and more resin.  I think it'll work.  Ok I hope it'll work.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Funderb on April 03, 2012, 02:59:38 AM
sometimes, when resin cures, which it does very fast in hot weather, it leaves a waxy film on top that will prevent future coats from sticking properly. We always wiped down with acetone real quick, just before we got glassing again. Just a thought! might save you some of these things: "@$%^%*^%$#@#$%^^&&"  :technical: :technical: :technical:

 :D
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: ben2go on April 03, 2012, 03:37:50 AM
sometimes, when resin cures, which it does very fast in hot weather, it leaves a waxy film on top that will prevent future coats from sticking properly. We always wiped down with acetone real quick, just before we got glassing again. Just a thought! might save you some of these things: "@$%^%*^%$#@#$%^^&&"  :technical: :technical: :technical:

 :D


That is called amine blush.Here's more info on it. http://www.westsystem.com/ss/assets/Uploads/Ew20Contamination.pdf
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on April 03, 2012, 06:08:40 PM
I thought about that Shep.  929 forks swap,.....   I don't know how hard that'd be though. 

How's your beast doing?  Need to do a good video of you cruising around.  I've never seen Croatia before, that'd be awesome!
Yeah, I know, I've promised 'em vids so long ago, but the trouble is, I don't have any kind of camera, except the one via cell-phone.
I got a friend that has some GoPro stuff, so hopefully when he gets back (he works on LNG ships), I'll post a vid or two.

About the bike... I'm still smiling every time I push the starter button (nuff said :icon_mrgreen:).

Oh yeah, last week I've pushed it to 200 km/h, and the rpm's seemed a bit high (around 10k), so I figured "well, you can't have it all"... only to realise I was still in 5th gear...  :icon_mrgreen:
The wind was just too strong, and me so concentrated not to get into wobble, to remember the gear I was in, so... well... maybe next time.  :icon_mrgreen:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on April 03, 2012, 06:34:44 PM
I can't wait to hear it while your cruising Shep!  I hope your bud will let you borrow it soon.  Awesome that you are cruising and having a great time on it!!!!  :bowdown:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on April 04, 2012, 02:34:56 AM
Tonite threw my foam molds,...in the trash,....sigh.  Messed around with some light metal and tin snips and may try that.  Just a simple panel riveted to a bracket tucked inside.  Seemed like it was coming out well.  'Light metal' is actually the cases from battery chargers we have at work that crap out and go into the parts pile.  They have louvres on the side which I thought might be interesting if I can work that piece in. 

Yes xune, failed you on foam.  arg

Also, so much for gorilla glue!  Giant crack appeared since I mounted it, so peeled off the gorilla glue and used Rapid Fix to redo it.  I should have used Rapid Fix to begin with.


(http://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash3/522679_3670772291195_1331504559_3500311_1459328012_n.jpg)

(http://sphotos.xx.fbcdn.net/hphotos-ash3/536279_3670747090565_1331504559_3500308_845878860_n.jpg)
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: xunedeinx on April 04, 2012, 04:03:09 PM
You didnt fail me, it was a good attempt!

Still anxiously waiting for a video of it running round the block.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on April 05, 2012, 02:47:24 PM
Me too xune.  You hold the camera.  Good stuff on your write up on the 1200cc by the way!

Yesterday, redid my fender and just about finished it up.  Did the final disassembly on the 929 to get that out of the way.

(http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash3/535636_3679405667024_1331504559_3503071_888039373_n.jpg)

Had a question,.....originally I had wanted to stuff that 929 into my F2, but reconsidering finding a GS frame and shaZamming it in there.  OPinions?  Pinwall has some cheap ones listed on ebay.  Just thinking about it cause it is sitting there doing a whole lot of nothing.

(edit) Steez has one available (see below) that could work out, and also found one locally for dirt cheap with a title.  Starting to visualize this,.....need opinions!
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: steezin_and_wheezin on April 05, 2012, 03:08:20 PM
HAHA thinking of the next build before the currents done, I like it!!

I have a complete titled 96 frame(primer'd) if yer interested?
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: xunedeinx on April 05, 2012, 05:48:50 PM
DO ETTTT! :cheers: :thumb: :thumb: :thumb: :thumb:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: mysterious_rider on April 11, 2012, 04:07:04 PM
bikes looking damn good! You just need a super fat wide tyre now.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on April 11, 2012, 05:10:25 PM
Gracias mysterious.  Been working on my panel idea.  I took a bunch of pics but this one pretty much sums it up.  I need to get some rubber trim and haven't figured out where to get it yet.  A bracket down low and one in the front hold it tight.  Not sure how I'm liking it yet but I'll wait to paint it before I decide.

(http://sphotos.xx.fbcdn.net/hphotos-ash3/560635_3720170566121_1331504559_3524759_110934312_n.jpg)

Started working on another set of carbs for my 600.  Need to finish the right side panel,...need more time in the day!
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: steezin_and_wheezin on April 24, 2012, 02:52:15 PM
took me a second to realize you were holding the filler panel!

i think that looks great from that angle, other than the louvers(which i really like the look of!) you can hardly tell its not stock. looks like it belongs there

Any updates for us?
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on April 24, 2012, 03:52:32 PM
Been working on it and sewing it up.  Figured I make some worthy progress before posting again.  Saw that I was at page 20, it's Springtime and I'm still not done, so want to get on it already.  Trying to make my next post as close to finished as possible.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: steezin_and_wheezin on April 24, 2012, 04:14:39 PM
Awesome, didn't realize you were that close to the final product! We don't mind quick updates, I just love following the progress of builds

Hell i was updating my build thread when i had just a shop full of parts and no GS!! haha
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: xunedeinx on April 26, 2012, 12:54:24 AM
I beat ya to it, and for less time any money!!

(600+ cc sportbike, that is.)
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on April 26, 2012, 01:41:09 PM
Damn straight you did sir and mighty fine acquisition!!!  Looks HOT HOT HOT in your living room.  SEXXXY!
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on April 29, 2012, 03:17:09 AM
Wasn't going to update til I was closer to being done but I liked this pic.
(http://a8.sphotos.ak.fbcdn.net/hphotos-ak-snc7/156199_3862537605208_1331504559_3574708_983236879_n.jpg)
Worked on it as much as I could today.  Going to do a quick spray and then come back later for details.  Ordered rubber trim from McMasterCarr to finish my panels with.  Today redid the tail bracket my son made to make it a part of the tail instead of bolted to the frame.  Finished my idea for the front which was something of a pita.  I want to paint it first before posting pics of that monstrosity.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: knowles on April 29, 2012, 03:40:44 AM
Nice when you going into production on the tails?
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: xunedeinx on April 30, 2012, 04:46:52 AM
Thats pretty sweet.

Just worth mentioning though, with my 180 rear I have now, with new michelin pilot power's, It can break the rear end loose.

Gunna be fun hitting 10k rpm with the 140 rear!
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: xunedeinx on May 07, 2012, 05:01:46 AM
Too long without an update. Are you done yet??
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on May 07, 2012, 05:00:00 PM
Screwing around painting.  Tank turned out to be a total mess.  Used stripper which didn't even get through the nineteen layers of crap paint & bondo that were on it.  Ended up, wire wheel on a grinder, attacking it.  Here's after I took my glove off,....

(http://sphotos.xx.fbcdn.net/hphotos-ash3/535201_3952249887959_1331504559_3602740_2137816374_n.jpg)

After I redo the tank then I'll put it all together and post pics.  Finally.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: adidasguy on May 07, 2012, 05:58:48 PM
Gracias mysterious.  Been working on my panel idea.  I took a bunch of pics but this one pretty much sums it up.  I need to get some rubber trim and haven't figured out where to get it yet.  A bracket down low and one in the front hold it tight.  Not sure how I'm liking it yet but I'll wait to paint it before I decide.

If you're talking about rubber trim around the bottom of the tank, that's a stock item. Order from any Suzuki dealer. One pack is enough for 2 tanks.
04+ has same trim but they were cheap and put it only at the front. Probably saved them a whole 25 cents in manufacturing. 89-00 used it all around the tank.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: yamahonkawazuki on May 20, 2012, 07:20:01 AM
Gracias mysterious.  Been working on my panel idea.  I took a bunch of pics but this one pretty much sums it up.  I need to get some rubber trim and haven't figured out where to get it yet.  A bracket down low and one in the front hold it tight.  Not sure how I'm liking it yet but I'll wait to paint it before I decide.

If you're talking about rubber trim around the bottom of the tank, that's a stock item. Order from any Suzuki dealer. One pack is enough for 2 tanks.
04+ has same trim but they were cheap and put it only at the front. Probably saved them a whole 25 cents in manufacturing. 89-00 used it all around the tank.
actually cheaper tbh to get some rubber door edge molding from a car parts house ( it fits perfectly. i used the chrome one on my first 97 gs. pretty much same stuff and cheaper versus dealer orders.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Funderb on May 20, 2012, 09:02:32 PM

(http://img.photobucket.com/albums/v202/funderburk/waiting-skeleton-meme-generator-cbrfxr-will-deliver-i-m-sure-of-it-lets-just-wait-bb5a1c.jpg)


:D


just kidding. take your time. my fzr is still sitting and rusting in the back yard.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on May 22, 2012, 07:55:19 AM

(http://img.photobucket.com/albums/v202/funderburk/waiting-skeleton-meme-generator-cbrfxr-will-deliver-i-m-sure-of-it-lets-just-wait-bb5a1c.jpg)
:D

just kidding. take your time. my fzr is still sitting and rusting in the back yard.
:icon_mrgreen: :icon_mrgreen: :icon_mrgreen:
He does take his time...

Somehow, I feel guilty for completing mine in just 20 days.  :icon_mrgreen:
So far, over 6000 kms of pure pleasure.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Funderb on May 22, 2012, 12:59:48 PM
Your build went badassedly smooth. lucky dog. Turns out the 'fzr1000' I bought has a yzf750 engine in it with one set of bad rings....

How much work do ya think it'd be to put that thing in the gs? :D I might actually measure it and see, I'm pretty sure its too big tho..
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on May 23, 2012, 02:36:46 PM
TOO funny Funder/Shep!!
And I've been piddling here and there.  Had to redo the tank and still not happy with it but will have to do for now.  I want to get on with it.  Still uncertain about the front.  My son says it looks really weird.  We'll see.  May pull it all off and go with a streetfighter 'mask' later.

Was trying to incorporate my louvre theme into the tail but my subframe is messing up my idea for using the metal panels.  Just wouldn't cooperate so I got Tomb rage and threw it in the trash.
(http://sphotos.xx.fbcdn.net/hphotos-ash3/524865_4061540220149_1331504559_3649800_94286072_n.jpg)

Tried using a piece of plastic sheet that seems to be okay.  Riveted some metal pieces to the inside to give it more sturdiness.  I think I'll go with this.  (Will refinish it in black or bedliner or undercoating)(I like this pic, how the F2 is lurking in the background)

(http://sphotos.xx.fbcdn.net/hphotos-snc7/45311_4061539620134_1331504559_3649799_686012484_n.jpg)

And very true Funder!  Shep's build was like spreading butter,...smooth and easy.  Sure Tesla is a genius but still a great build & riding in no time! 
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on May 28, 2012, 10:07:24 PM
Worked on bringing it all together yesterday.  Opinions welcome.

(http://sphotos.xx.fbcdn.net/hphotos-ash4/379232_4095974400982_357120296_n.jpg)

(http://sphotos.xx.fbcdn.net/hphotos-snc7/319861_4095975040998_1459057674_n.jpg)

(http://sphotos.xx.fbcdn.net/hphotos-ash3/559969_4095973840968_799342419_n.jpg)

(http://sphotos.xx.fbcdn.net/hphotos-ash4/487178_4095975241003_1872247690_n.jpg)

(http://sphotos.xx.fbcdn.net/hphotos-ash3/533457_4095974600987_1331504559_3666333_1469941573_n.jpg)

(http://a5.sphotos.ak.fbcdn.net/hphotos-ak-prn1/538878_4095975361006_2119854958_n.jpg)

Still have front blinkers and some odds and ends to put together but just about done.  Finally,...haha
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: codajastal on May 28, 2012, 11:33:55 PM
Apart from the weirdo on the bike I think it looks awesome and really MEAN :thumb:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: mattnes17 on May 29, 2012, 07:04:18 AM
Everything looks great but the front headlight set up. Just no my style. Amazing work tho man  :thumb:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on May 29, 2012, 12:04:12 PM
Everything looks great but the front headlight set up. Just no my style. Amazing work tho man  :thumb:
+1  :thumb:

Nice work on hiding that hole between the frame and tank, I like those Mad Max style builds.
But the whole package is a bit spoiled by that front headlight for me.
Just my opinion.

Maybe Triumph-style double f/lights for a change?

And you definitely need a wider rear tyre.  :thumb:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on May 29, 2012, 02:01:30 PM
Thanks Cods.  Tried to find some hot broad walking by the shop but sorry, got stuck with this homeless guy. 

I wasn't sure about the front either but I think I'll leave it that way.  Just different and make you think 'wtf is that?'

In the end came down to: GS500, Cbr F3 engine, F2 carbs, 900rr tank, dirtbike radiators, 600rr tail, gsxr fender, and homebrewed panels made from old battery charger panels, oh and can't forget snowmobile headlight!

I'll get a video up soon when I can get a camera.  Wanted to mention, thanks to Shep, Tomb, and Xune.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: steezin_and_wheezin on May 29, 2012, 03:09:03 PM
LOVING it! keep that headlight for sure, makes it look mean

Great work mang, stoked on how it all came together! Only thing that gets me is the gs rear wheel in comparison to that beast RR tail. Still that's small stuff. The tail fits the bike, but the gs wheel leaves more to be desired..

That engine in the frame with the headlight, tank w/ louvers, and 600 tail looks f%$king awesome :bowdown:

Can't wait to see that video!!
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Funderb on May 30, 2012, 03:02:08 AM
dude. that looks...... awesome, i cant even put words to it. It is definitely a bike someone from GWAR would ride.

I dont see any fans on there, does the f3 motor stay pretty cool at idle? wondering if you'll run into any overheat problems when you're sitting still.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Guymo on May 30, 2012, 06:28:25 AM
+1 on the headlight. I like it, looks badass

also +1 on needing a bigger tyre hahaha. but i guess thats in the works
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on May 31, 2012, 03:43:35 PM
Thanks sincerely.  Yes will do the standard swingarm swap after I wear out the 'new' Avon on the back.  And fan is on the left side radiator.  Seems ok so far.  If I have issues during the Houston hell summer heat, will consider another set up.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on June 20, 2012, 03:08:39 PM
Well... on this very day, one year ago... the project was over after 20 days of work (4-5 hours a day).

To simply sum it up: 7771 kilometres of pure pleasure so far.

Last month I took a two day trip to Montenegro (800 kms overall), and on the way back discovered a beautiful route through Bosnia: great asphalt, lots and lots, and lots of bends, and almost no traffic... only downside was the rain almost all the way.  >:(

Latest upgrades:

Got for free some (slightly used) racing tyres, dual compound Michelin Power One (front 110, rear 160), and after the warm-up, the grip is just unbelievable.
Purchased (but not yet installed) the new handlebar (cuz the old one's a bit bent).
Mounted softer rear brake pads (better braking, and less squeaking).
I've cut a piece of old rubber car floor carpet and made a mud guard for rear shock muck/dirt/allothershit protection (how the hell Suzuki haven't thought of that is a mistery to me).

Well... it's (hot) summer over here, and the bike's waiting in front of the house, so...

Oh yeah, here are a couple of freshly fresh pics, and while taking 'em, I've noticed a crack in my windshield  :sad:, must've been some fatass bug (R.I.P.), who knows.

(http://img441.imageshack.us/img441/6356/dsc01261nf.th.jpg) (http://imageshack.us/photo/my-images/441/dsc01261nf.jpg/)
(http://img690.imageshack.us/img690/281/dsc01264hz.th.jpg) (http://imageshack.us/photo/my-images/690/dsc01264hz.jpg/)
(http://img401.imageshack.us/img401/4894/dsc01262jg.th.jpg) (http://imageshack.us/photo/my-images/401/dsc01262jg.jpg/)
(http://img193.imageshack.us/img193/6238/dsc01260fn.th.jpg) (http://imageshack.us/photo/my-images/193/dsc01260fn.jpg/)
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on June 20, 2012, 04:12:10 PM
 :bowdown:  Thanks for the update Shep!  Rocking pictures too!  :thumb:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: steezin_and_wheezin on June 20, 2012, 05:29:56 PM
Did i miss the video?? I fiend for it :icon_lol:
Title: Re: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on June 20, 2012, 05:56:29 PM
Did i miss the video?? I fiend for it :icon_lol:
Nope, never actually made any.
Have no camera, nor way of mounting cellphone.
Shrug.
If I ever make one, I'll post it here first.

Sent from my toilet seat using HTC FartPhone
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: iclrag on July 11, 2012, 05:38:45 PM
niiiiiice! im jealous   :D
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Funderb on July 13, 2012, 01:44:00 AM
dude, just grip the phone firmly in your teeth and go for a ride. :D

or just video it cranked up and running hot!

doooo iittt!

please.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: trinacria on July 14, 2012, 04:38:45 PM
Worked on bringing it all together yesterday.  Opinions welcome.

(http://sphotos.xx.fbcdn.net/hphotos-ash4/379232_4095974400982_357120296_n.jpg)

(http://sphotos.xx.fbcdn.net/hphotos-snc7/319861_4095975040998_1459057674_n.jpg)

(http://sphotos.xx.fbcdn.net/hphotos-ash3/559969_4095973840968_799342419_n.jpg)

(http://sphotos.xx.fbcdn.net/hphotos-ash4/487178_4095975241003_1872247690_n.jpg)

(http://sphotos.xx.fbcdn.net/hphotos-ash3/533457_4095974600987_1331504559_3666333_1469941573_n.jpg)

(http://a5.sphotos.ak.fbcdn.net/hphotos-ak-prn1/538878_4095975361006_2119854958_n.jpg)

Still have front blinkers and some odds and ends to put together but just about done.  Finally,...haha

The build is amazing but I gotta admit that the headlight is a bit on the rough side. Ofcourse if you like it go with it and I appreciate you trying to match it with the rest of the bike but it looks like its out of place. Still, I would nominate you for the gstwins hall of fame, probobly the most complex built ive seen
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on July 14, 2012, 11:36:23 PM
Thanks trin.  I learned a great deal working on this build.  I'd encourage anybody who likes riding and bikes, to pick up a project and dig in.  The gs is a great bike and not so complex that the average person can't easily use this forum and start figuring things out. 
 :whisper: (i am actually making a teeny tiny change to this GS at the moment, pics soon)
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on July 21, 2012, 07:37:13 AM
(http://img.tapatalk.com/59c9ea11-5c1d-f607.jpg)

(http://img.tapatalk.com/59c9ea11-5c3c-507e.jpg)

8)


Sent from my toilet seat using HTC FartPhone
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on July 21, 2012, 01:41:47 PM
Can stare at that airbox for an hour Shep,....details, details.  I think I'm going to do like xune suggested using a car air box and flat filter on my new set up.  Was re-reading old posts and  realized xune was full of good ideas back then. 
Your bikes looking sweee-eeeet as always good sir.  :thumb:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Phil B on July 21, 2012, 01:46:05 PM
Was re-reading old posts and  realized xune was full of good ideas back then. 

as opposed to now, you mean  :icon_razz:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on July 21, 2012, 02:12:43 PM
Although I tried to make things simple, the GS' airbox is just too small, and even with modified (widened intake port) K&N drop-in filter, the bike was running out of air at around 10k rpm (noticed in 2nd and 3rd gear).

So... took the whole thing out, mounted lunchbox, and now it seems ok.
Now it gets to 12-13k with no problem.
Took it for a spin, and just licked the 180 km/h mark at 12k in 3rd gear (and that was uphill).
Then I had to brake (hard) for the traffic light. :)

Only downside (if I can call it that way) is the intake growl that's almost as loud as the exhaust (at full throttle), so the bike sounds like an F1 car with a sore throat.

I definitely have to make a video of it.


Sent from my toilet seat using HTC FartPhone
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: knowles on August 05, 2012, 08:04:36 PM
I like it, but ya the rear tire and the headlight look different. but the stuff you over came is awesome. I tip my hat to you sir. Every thought of just putting like GSXR fairings on it to have a sleeper?
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on August 06, 2012, 12:22:35 AM
Hey knowles,...thanks and actually doing some small changes.  I'm keeping track of pics and details and will post it all when I get it sewed up. 

I think one thing it gave me was an appreciation for the original gs.  After doing it and figuring out how to make something work that was never intended for where it ended up, I look at my stock gs and smile.   :D
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: yamahonkawazuki on August 06, 2012, 12:48:35 AM
Shepa, i remember the original writeup on this. was wondering whatever happened. now we know. do you own a camera, if so ill send you a mount for it. free of charge. let me know.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on August 06, 2012, 10:07:34 AM
Shepa, i remember the original writeup on this. was wondering whatever happened. now we know. do you own a camera, if so ill send you a mount for it. free of charge. let me know.
The thing is, I could make a video with my cellphone, or some Sony CyberShot I have somewhere, but in fact... I'm just too lazy to figure something out, compared to riding...
When I throw my leg over the seat and start the engine, the last thing on my mind is video, sorry...  :angel:

I'll have to ask Tesla or somebody, to make a flyby video (maybe, just maybe even today), and if that comes out right, I'll make that gs-wiki DIY camera holder for this CyberShot of mine.
I promise.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on August 09, 2012, 02:51:48 PM
I just can't resist sharing with you guys.  I'm having a blast with this!  I was going to keep a log and post it all after I was done but too much fun not to share.  I love this stuff.  Comments welcome as always,.....
(http://sphotos-b.xx.fbcdn.net/hphotos-snc6/165926_4212601636590_275646133_n.jpg)

Rebooted my project after breaking a T in the carburetor and sick of dealing with carbs. Started stripping the frame. Pulled most of wiring and cooling system. Tonight want to drop engine and rest of miscellaneous & get ready to figure out how to start on 929 install.

(http://sphotos-b.xx.fbcdn.net/hphotos-ash4/229986_4217717324479_1146686580_n.jpg)

Finished dropping the engine and stripping odds and ends. Thinking of completely cutting off the tail and redoing it. Working on lining up a gas mig to fab with instead of my old stick. May drop the swingarm and forks to have better maneuverability on fabbing up supports for 929 engine.

(http://sphotos-a.xx.fbcdn.net/hphotos-prn1/562146_4223019577032_491118422_n.jpg)
Strippin'
(http://sphotos-b.xx.fbcdn.net/hphotos-prn1/562146_4223019617033_1033351801_n.jpg)

You can see this is going to be a challenge to make this work. Going to be figuring out a new airbox set up for sure.

(http://sphotos-b.xx.fbcdn.net/hphotos-prn1/562146_4223019657034_438649873_n.jpg)

Removed the harness and started looking over where my support points are going to be. Still debating if it'd be easier to work with the frame minus forks and swingarm or do it the way I did the 600.

(http://sphotos-b.xx.fbcdn.net/hphotos-ash3/562146_4223019697035_408887686_n.jpg)

New cover. The old one has a nice crack in it. Ran out of time before I swapped over the stator.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on August 09, 2012, 03:39:46 PM
(http://sphotos-a.xx.fbcdn.net/hphotos-ash4/303545_4229087808734_262713981_n.jpg)

Replaced stator cover yesterday. Giant crack right there but hard to see in pic. Used factory gasket even though I've had great results with rtv. Figured I'd try the gasket since I had it already (From PO).
Scored a mig from work (thanks boss!) and need to get some gas and regulator since we are out. Thinking of using my engine hoist to maneuver engine around. Might be easier than wrestling with it and using my back like last time.

(http://sphotos-b.xx.fbcdn.net/hphotos-ash4/252761_4251264443136_145288538_n.jpg)

Picked it up off the floor with my hoist. I'm wondering if it will be easier to use the hoist to hold it up while angling it right in the frame. Today hope to get it more in position after I cut away my old mounts and the frame brace.

(http://sphotos-a.xx.fbcdn.net/hphotos-snc6/246547_4254878173477_1006357336_n.jpg)

Got the radiator off and it isn't much bigger than the 600 engine. Exhaust and airbox are going to be the tricky parts.

(http://sphotos-a.xx.fbcdn.net/hphotos-ash4/246547_4254878213478_41921039_n.jpg)

Lining up and looking for ideas on how to do it. I'm thinking of welding support bars that go to each mounting hole in the block then across to meet each other which would eliminate the lower frame brace that the factory used, enabling the engine to be part of the whole support structure. Will have to weld in added support as Shepa tried this with his 600 swap and the frame flexed.

(http://sphotos-b.xx.fbcdn.net/hphotos-prn1/539765_4285033567343_1060443017_n.jpg)

Cut out the engine mounts I made for the 600 and also Suzuki's as well. Left the two mid top ones. Next'll be to start lining it up and see how hard it will be to make it fit. Fun fun fun :)

(http://sphotos-a.xx.fbcdn.net/hphotos-snc6/283606_4285033847350_1546130596_n.jpg)
Cutting

(http://sphotos-a.xx.fbcdn.net/hphotos-ash4/318801_4299244602610_1527918710_n.jpg)

Finally got it set up after cutting more of the lower frame out. Even had to cut off the damn kickstand. Was pretty happy with how it lined up though. Even the lower exhaust cleared.

(http://sphotos-a.xx.fbcdn.net/hphotos-snc6/180259_4299245162624_1872008896_n.jpg)

Took this picture to do some sampling with my mad 'paint' skillz on how to connect the new supports/frame together. Not much clearance underneath here so I'll have to lift it up more but I don't want it like the 600, with no room for anything because it was so close to the frame.

(http://sphotos-a.xx.fbcdn.net/hphotos-ash4/486272_4319219581972_1128225354_n.jpg)

Extra wide. The blade's motor is offset which makes it even more asymmetrical in a conventional frame. I may have to counterbalance on the left side later, depending on balance issues. Funny how the throttle bodies still are close to center even when the majority of the right side is hanging out.  Guys on cf said it can't be done. pffffff


Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on August 09, 2012, 03:46:05 PM
(http://sphotos-a.xx.fbcdn.net/hphotos-ash4/380590_4319220381992_190829190_n.jpg)
Lining up sprockets.

(http://sphotos-b.xx.fbcdn.net/hphotos-snc7/600258_4319218861954_1964157389_n.jpg)

First bracket. I really enjoy making brackets, bending them and getting them to work. This was a piece of plate I found at work; thick and sturdy. Using it for the top bolt in's that I didn't cut out. Once I get these in, I believe I can roll the hoist out and just use the floor jack while working on the other mounts.

(http://sphotos-b.xx.fbcdn.net/hphotos-ash4/313949_4334399521461_235242108_n.jpg)

Bolted in my hangers yesterday which allowed me to remove the hoist. I may or may not keep the hangers in the end but for now they keep it in place so I can start welding in my mounts and finally frame triangulation to support the frame like the lower frame did stock.

(http://sphotos-a.xx.fbcdn.net/hphotos-ash3/548180_4334393641314_714061777_n.jpg)
Left side hanger.

(http://sphotos-b.xx.fbcdn.net/hphotos-snc7/309368_4384919304424_1840792987_n.jpg)

More bolt in supports. These are on the bottom using the center stand mounts.

(http://sphotos-b.xx.fbcdn.net/hphotos-prn1/531754_4384919784436_1260303384_n.jpg)

Center stand support mounts on the bottom, for bolt in mounts. May or may not leave these on after doing the weld in supports.
(http://sphotos-b.xx.fbcdn.net/hphotos-snc7/427397_4384918704409_1712132507_n.jpg)

First weld on support, upper middle. That shiny mess is where I cut off my old supports for the 600. Definitely clean it up eventually.

(http://sphotos-b.xx.fbcdn.net/hphotos-ash3/580993_4389372815759_656566228_n.jpg)

Made the second weld on bracket yesterday. Hope to weld these on this afternoon and work on the next pair. Then onto creating the front brace that will meet up with the cylinders on both sides.

(http://sphotos-b.xx.fbcdn.net/hphotos-snc6/268354_4398679408418_370324781_n.jpg)

Atd mig that boss gave me a deal on so I could get it. Wish I had this years ago!

(http://sphotos-b.xx.fbcdn.net/hphotos-snc7/315431_4398645967582_185732278_n.jpg)

Cutting out second pair of weld on supports. Got the first pair in yesterday. REALLY happy with atd mig. SUch a huge difference from what I had before. Tacking in mounts good and sturdy then will drop engine, weld them in solid, clean up and paint then put engine back in.


Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on August 09, 2012, 03:54:23 PM
(http://sphotos-a.xx.fbcdn.net/hphotos-ash3/555557_4407393786272_1683923555_n.jpg)

Made second pair of brackets yesterday. Came out good and once again mig so much easier to use in getting them welded on. Next is front frame add on, bent down to front mounts on cylinders. Will likely be the hardest part to make. Ordered 4 foot section x 1-1/8" with .065 wall, mild steel. Then decide on whether to reinforce frame for support or weld on lower triangulation (vfr style) for strength.

(http://sphotos-b.xx.fbcdn.net/hphotos-snc6/217908_4421952910241_172362909_n.jpg)

Got my steel in but somehow ordered 1 7/8" instead of 1 1/8". Maybe it was meant to be. It is pretty damn big. Figured I'd give it a shot nonetheless. If anything, make it a practice effort and then get some smaller diameter tubing. Cut into smaller lengths then beat the hell out of the end to make it flat, cut to taper, welded seam, drilled mount hole and set up with bushing. I'm hoping if I use this, blacked out, size wouldn't be too noticeable.

(http://sphotos-b.xx.fbcdn.net/hphotos-ash4/422228_4427053877762_553798650_n.jpg)
Welding seam on second mount.

(http://sphotos-a.xx.fbcdn.net/hphotos-ash3/549695_4427053477752_718946093_n.jpg)

Working on frame hangers. Not sure about these yet. They are pretty big. Maybe when it is all done and blacked out it'll give it a beefy look. Not sure.

(http://sphotos-a.xx.fbcdn.net/hphotos-snc7/481896_4427054117768_107487952_n.jpg)

Working on frame hanger. Trying to get it angled right. Trimming it to match the frame geometry is difficult.

(http://sphotos-a.xx.fbcdn.net/hphotos-prn1/533205_4431956480324_1702582223_n.jpg)
Welding right hanger together

(http://sphotos-b.xx.fbcdn.net/hphotos-ash3/553385_4431970200667_342591822_n.jpg)

I don't know, I'm kind of digging it. Kind of reminds me of a spider leg, or alien stabbing arm thingy. heheh
(http://sphotos-a.xx.fbcdn.net/hphotos-ash3/527071_4431970640678_268726698_n.jpg)

Not as obnoxiously noticeable now. I think with frame matching paint that it'll be good.
Set up and ready to weld to frame. Going to do the other side and then weld both onto the frame at the same time.

(http://sphotos-b.xx.fbcdn.net/hphotos-ash4/373967_4459964540508_911283270_n.jpg)
left side hanger,....working on angle with magnetic help.

(http://sphotos-b.xx.fbcdn.net/hphotos-ash4/479797_4459964780514_1365457037_n.jpg)

Topview. Thinking these will be excellent support to mold in and hold my dual radiators/shrouds.

(http://sphotos-b.xx.fbcdn.net/hphotos-prn1/625620_4459964980519_255598650_n.jpg)

Weld & blend. Next will be weld to the frame on both sides.

(http://sphotos-a.xx.fbcdn.net/hphotos-ash3/539159_4464621816937_1548216788_n.jpg)

Couldn't use the hoist to get the engine out. The holes I need to use now are used by the hangers. The ones I used before were too close to frame add ons. So did it this way cause I didn't want to stress my tack welds.

(http://sphotos-b.xx.fbcdn.net/hphotos-ash4/226214_4464728539605_2126445284_n.jpg)

Took it outside to get better pic of supports. Looks like it has no guts. Total it has TEN mounting points to the frame. I think that's enough.

(http://sphotos-b.xx.fbcdn.net/hphotos-ash4/304636_4464508694109_314487906_n.jpg)

Started welding in my strong welds. Even the tack welds were so much better than what I'd done before. Amazing difference in welders.
Really like how tapping it with the hammer goes from 'tink tink tink' to 'donk donk donk' after you weld it up.


Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: knowles on August 09, 2012, 04:30:59 PM
WOW i like it. wish you lived around me so i could have you weld the bracket on the steering tube so i could finish my faring project. i like to see someone doing something different. keep going. HAve you thought about just making a frame from scratch? jsut a thought :thumb:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on August 09, 2012, 05:24:13 PM
Hey knowles,...title & paperwork scares me to go full on BUILD like that.  I have clean paperwork on the GS so I chose to reboot from the 600 instead of do something different & continue dealing with those jacka** carbs. 

Definitely WANT and trying to build something different.  If it works cool, if not, figure out another way to make it work.

And we could weld that thing on in ten minutes.  Sometimes I wish somebody lived close by just to hang, ride, build, bs, with.

Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on August 10, 2012, 02:48:50 PM
(http://sphotos-b.xx.fbcdn.net/hphotos-ash3/s720x720/532964_4468573315722_1486341641_n.jpg)
Just welding up the supports.  Did right side yesterday,...

(http://sphotos-b.xx.fbcdn.net/hphotos-prn1/s720x720/539059_4479101658924_1740224506_n.jpg)
Worked on welding up the left side today. Cleaned up welds and now will redo a couple of small spots then prime all the brackets out and go to next step.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: steezin_and_wheezin on August 10, 2012, 02:58:00 PM
yeah! will be looking this over closer next week when i have a spare hour!! looks great so far mang :thumb:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on August 14, 2012, 02:06:16 PM
(http://sphotos-b.xx.fbcdn.net/hphotos-ash4/s720x720/183783_4485654862750_1171461030_n.jpg)
Yesterday cleaned up welds, then re-did a few spots.  Wire wheeled & flap disk then painted them with a heavy coat of black enamel.  Not sure if I'll come back and paint or just leave it this way.  Ready to put engine back in and get to work on the air box.  Last time I saved the airbox for late in the build & it confounded me for quite awhile.  This time I want to start on it first.

(http://sphotos-b.xx.fbcdn.net/hphotos-snc6/215464_4490752910198_1664923265_n.jpg)
kickstand

(http://sphotos-a.xx.fbcdn.net/hphotos-ash3/s720x720/527172_4490752750194_780912428_n.jpg)
Putting engine back in. Left side didn't line up and wasn't obvious 'why.' Ran out of time before I could get the left side frame add-on bolted in. All the rest lined up great. Very easy to take it out or install.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Funderb on August 19, 2012, 03:01:38 AM
you're shitting me! did you even ride the previous one? you're crazy! hahaha
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Phil B on August 19, 2012, 04:07:11 AM
you're shitting me! did you even ride the previous one? you're crazy! hahaha

He's just practicing for his REAL target:

(http://www.transportspecs.com/images/motorcycle_cylinders/boss_hoss_big_block.jpg)
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on August 19, 2012, 02:08:26 PM
Phil I've often wondered what the range would be on a bike like that!  And Funder, nothing to brag about.  Went to change up some fuel lines and cracked a T in the bank and stood there for a few minutes cursing.  Finally gave the 600 the bird and started taking it apart.

(http://sphotos-b.xx.fbcdn.net/hphotos-snc6/254892_4508112504177_1125152380_n.jpg)
Trim, trim and trim somemore. The frame being so close on each side makes this a real annoying feat.

(http://sphotos-a.xx.fbcdn.net/hphotos-ash4/246841_4508112784184_1509823489_n.jpg)
Cut the velocity stacks in half to see if they'd fit.

(http://sphotos-a.xx.fbcdn.net/hphotos-ash4/482086_4508112624180_1513920000_n.jpg)
Kept cutting. Ended up with a gasket for the grooves in the throttle body. Made a 'rough draft' box that sits on top of this but phone battery died and didn't get pic. I think when I rebuild the box in straight material, it will work. Completely based on Shepa's design.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: xunedeinx on August 22, 2012, 03:46:41 AM
I want an R1 powered gs.... :thumb:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on August 22, 2012, 01:51:14 PM
xune!  Honored at your presence good sir!

(http://sphotos-b.xx.fbcdn.net/hphotos-ash4/419890_4523500928878_1340113463_n.jpg)
One from last week as I was whittling it down to see how much I could keep.

(http://sphotos-b.xx.fbcdn.net/hphotos-ash4/420022_4523501368889_1571825338_n.jpg)
Template for my box. Worked on this for quite awhile last week. Ordered some clean new plate to redo it and also make the top portion. Planning to cut a hole then pod filter mounts on that.

(http://sphotos-b.xx.fbcdn.net/hphotos-snc7/293021_4523501128883_1789234507_n.jpg)
Got my front 16t x 520 yesterday so checked it with the chain. Unfortunately chain is prob going to be too short so will get another one sooner or later.

(http://sphotos-a.xx.fbcdn.net/hphotos-ash4/253974_4523501568894_729991689_n.jpg)
There is ALOT of room under the tank. Will have to remake some panels to cover cavernous gaps. Was going to move battery to the tail and re-do it, but it will mount under tank easily, along with electronics and spare tire, toolbox maybe couple extra helmets,..ok it just seems that big under there.  :laugh:

(http://sphotos-b.xx.fbcdn.net/hphotos-snc6/183690_4523500528868_2000457482_n.jpg)
I don't particularly like the lines of this tank compared to the 900rr tank but the fuel pump is IN the 929 tank, so not much I can do otherwise.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: bombsquad83 on August 22, 2012, 02:24:01 PM
Kinda looks like a hump back whale.  Any way to get the fuel pump out of the tank?
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: GI_JO_NATHAN on August 22, 2012, 03:38:10 PM
Liking it all... except the tank of course.

This bike is begging for USD forks and a different swing arm.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: JollyRojer on August 22, 2012, 03:45:02 PM
whew ya that tank would make riding for somone like me a pita (5'4) but its your bike long as its comfortable go to town, browsed this entire build you do some very clean clean work, this gs is my first bike (and attempt at bike mods) but im no stranger to fabricating good to see somone else doing some serious fab work on these lil rockets.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on August 23, 2012, 01:37:12 PM
(http://sphotos-b.xx.fbcdn.net/hphotos-ash3/s720x720/527073_4528229967101_813586220_n.jpg)
bomb I don't think it'd be worth the aggravation to try and make it work in another tank.  I guess it's possible but  :mad:
(http://sphotos-a.xx.fbcdn.net/hphotos-ash4/298854_4528230247108_1664238421_n.jpg)
Still waiting for my material so turned to the tank.  I've fixed a few crapped out tanks before but I'm not sure about this one.  REALLY f'd up.  Terrible bondo job from whoever had it previously.  The bondo isn't the hard part, the whole tank is whopped.

(http://sphotos-a.xx.fbcdn.net/hphotos-snc7/418611_4528230607117_332121823_n.jpg)
No prep, no nothing under this huge glop of bondo/fiberglass resin.  Couple of prys and it popped right out.  How the hell do you get a dent like that anyway??  And I wonder how much gas capacity is lost from it,......(facepalm)

Hey jolly, welcome to the forum!  I like to think I DW like any average guy in his garage, no cnc, no plasma cutter, no high end stuff, just basic tools and figuring out how to make it work.  Thanks for the comment!  Opinions always welcome.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: GI_JO_NATHAN on August 23, 2012, 06:13:28 PM
Wow. I think you should post that in the "Epic Fails" thread..
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on August 24, 2012, 02:02:46 PM
GI, I just wonder how it happened?  Pole?  Fence?  Knee before it was crushed? 

Got my material in yesterday but (of course) started to think of other ways to make it.  Drew out some plans then got an idea to make stacks on a plate that sit on the throttle body.  The velocity stacks are there for a reason, and with the stacks, I wouldn't have to make a 'cover' for the box, to be able to access the screws that hold it on.  Trying to make it as simple as possible.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: knowles on August 25, 2012, 04:30:23 AM
Hey knowles,...title & paperwork scares me to go full on BUILD like that.  I have clean paperwork on the GS so I chose to reboot from the 600 instead of do something different & continue dealing with those jacka** carbs. 

Definitely WANT and trying to build something different.  If it works cool, if not, figure out another way to make it work.

And we could weld that thing on in ten minutes.  Sometimes I wish somebody lived close by just to hang, ride, build, bs, with.
(http://sphotos-b.xx.fbcdn.net/hphotos-ash3/s720x720/527073_4528229967101_813586220_n.jpg)
bomb I don't think it'd be worth the aggravation to try and make it work in another tank.  I guess it's possible but  :mad:
(http://sphotos-a.xx.fbcdn.net/hphotos-ash4/298854_4528230247108_1664238421_n.jpg)
Still waiting for my material so turned to the tank.  I've fixed a few crapped out tanks before but I'm not sure about this one.  REALLY f'd up.  Terrible bondo job from whoever had it previously.  The bondo isn't the hard part, the whole tank is whopped.

(http://sphotos-a.xx.fbcdn.net/hphotos-snc7/418611_4528230607117_332121823_n.jpg)
No prep, no nothing under this huge glop of bondo/fiberglass resin.  Couple of prys and it popped right out.  How the hell do you get a dent like that anyway??  And I wonder how much gas capacity is lost from it,......(facepalm)

Hey jolly, welcome to the forum!  I like to think I DW like any average guy in his garage, no cnc, no plasma cutter, no high end stuff, just basic tools and figuring out how to make it work.  Thanks for the comment!  Opinions always welcome.

If yo did my wife would be even more mad because after working midnights and going to school during the day i wouldnt see her if a guy lived close to me that had a gs. :cheers:

I would either get a new tank or split that sucker and pound the dent out, maybe you should make one. i get lucky because i can bring my bike to class and work on it with just about any tool you could ever need. :woohoo:.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on August 26, 2012, 04:16:28 PM
Hell ya knowles on DW at class!  :thumb:

(http://sphotos-b.xx.fbcdn.net/hphotos-ash3/s720x720/547076_4545748725059_1248193423_n.jpg)
This is my idea to clear the mounting bolts (pita) and the fraime on each side plus incorporate the 'velocity stacks' into the box.

(http://sphotos-b.xx.fbcdn.net/hphotos-ash4/255570_4545748645057_909003982_n.jpg)
Bottom half. Need to clean it up but ran out of time. Next will be the actual 'box' across the top with filter on it.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: knowles on August 30, 2012, 01:40:23 AM
too bad there isnt a way to go out the sides and front for Vmax style.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on August 30, 2012, 01:42:42 PM
Good idea knowles.  Was thinking something like that with the way the tank has gaps on both sides and the 929 airbox is set up for ram air,....when I redo the panels I want to put some 'scoops' to bring air in. 
(http://i2.photobucket.com/albums/y17/xdarkdrake/rant.gif)
I haven't gotten a chance to DW all week and its' aggravating as F.  SOrry rant done.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on September 01, 2012, 01:13:21 AM
Finally got to mess around abit today.  Got the top piece cut out and ran out of time again.
(http://sphotos-a.xx.fbcdn.net/hphotos-ash3/s720x720/527192_4572132544638_195179167_n.jpg)
Next will weld it up slowly and then keep going, making the sides. 

And more yeserday,...

(http://sphotos-b.xx.fbcdn.net/hphotos-ash4/393398_4577844567435_1734774107_n.jpg)

(http://sphotos-a.xx.fbcdn.net/hphotos-ash3/546126_4577844687438_1267224742_n.jpg)

(http://sphotos-b.xx.fbcdn.net/hphotos-ash3/526327_4577844167425_653365238_n.jpg)
Next will be to clean it up more, then locate the right filter and paint it.

Quick tip (from cf) is to score the back side of your sheet of metal and bend it to the shape you need it.  I was going to cut it, then weld it back but saw a guy on cf who is adding to his gas tank and he scored the backside, then hand shaped the sheet metal to how he wanted it.  Much easier.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on September 03, 2012, 10:58:50 AM
Oi mate!
Why not use the external fuel pump, like on F3?
More volume in the tank.
Just a thought.



Sent from my toilet seat using HTC FartPhone
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on September 10, 2012, 01:57:22 PM
Leave it to Shep for good ideas.  Considering that, finding the specs for the fuel pump delivery pressure and finding another pump that is the same rating, I think it would work.

(http://sphotos-a.xx.fbcdn.net/hphotos-snc7/s720x720/301103_4615495268679_459912646_n.jpg)

Did more work on my box.  Yes that's a gs filter.  Needed something to mount there for reference for the time being.  Figuring out how to bring in the breather tubes now.  I was thinking a 1/2" T, bringing the two hoses from the top of the valve cover together then take the single to the box.
Took out the harness and laid it out to start install.  Pretty straight forward stuff.  Checking the throttle bodies out yesterday, was surprised to see how many vacuum hoses T into each other.  Two off #1, then 2,3,4, all have one that T's out from there.  Also the system that controls the valve in the exhaust has to be mounted somewhere.  Fun fun fun.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: steezin_and_wheezin on September 10, 2012, 04:09:50 PM
looking good mang!!
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on September 10, 2012, 04:35:45 PM
I like your box design, but I'm suspecting (wish I was wrong) an air starvation issue I was having with mine.
Especially with only one intake hose (and considering cubic capacity of the engine).

Seems like only first two cylinders will have enough air, the other two will run rich (nevermind the EFI).

Remember that the CBR was designed to run on "static air", hence the huge original airbox, which is now missing.

Is it possible to make two intake ports (possibly simetrical, so that air fills all 4 cylinders equally) and fit K&N lunchbox?

I may be sounding like a partybreaker, but in my case, it was all trial and error, till I got it right (I hope).
And that was just messing with different air-filters.

Keep up the good work, man!
Can't wait to see it run!



Sent from my toilet seat using HTC FartPhone
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on September 10, 2012, 05:12:48 PM
You're probably right as you usually are Shep.  The top of the 929 box is definitely large but inside it has a solenoid with a flap controlling air flow.  It also has two small intake (ram) air tubes on each side.  I'll have to see what happens with this and decide what to do after I get it going.  Glad for your comments and input anytime!

Steez!  Thanks for stopping by!  :icon_mrgreen:



Wednesday went and found some T's to sum up the breather hoses and got those hooked up to my box yesterday.  Messed around with where I'm going to put the battery.  Lots of room under there but I want to be able to get to stuff without taking crap apart.



Been working on locating where the harness is going to go.  Started, stopped, started, stopped.  Concluded I'd start with relocating the battery to under the solo cowl and then take it from there.  I don't want to jam it under the tank and this will give me super easy access to it.  Cut out a small section and fit it.  Going to weld in a cross piece and sit on top of a aluminum cut out. 

(http://sphotos-b.xx.fbcdn.net/hphotos-snc7/385669_4655600911295_248156684_n.jpg)



Been working on routing electrical all week.  Got the battery set up nicely in the tail section and started bringing the wiring back from there.  Used the undertail/ecu holder from the 929, cut it down and storing alot of the wiring and 'extra' in it.  The ecu fits it perfectly so makes sense to keep it. 



Whole bunch of nothing to report.  In the process of trying to move so going to be spinning cobwebs for awhile.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on December 28, 2012, 02:58:09 PM
Hey dude, any work in progress?


Update on my project bike:

Almost high-sided last week.
Morning rush to work, cold tires, cold road, a little bit more throttle than needed, and the rear slid to the right, bike landing to the left, and I landed on my back.  :icon_mrgreen:

50 meters from my home.

Result: snapped clutch lever, grinded magneto cover (no oil leak), bent shift lever... and that's about it.
Luckily there were no youtube-friendly-passers-by, or I'd be as popular as this guy:

https://www.youtube.com/watch?v=Q9zNUPDmnz4
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: ryott52 on December 28, 2012, 05:49:15 PM
Hey man, have you considered adding a different front end? Maybe something with slightly better brakes than the stock GS? That's going to be a lot of power to try and hold down with one disc.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on December 28, 2012, 09:12:24 PM
Hey Shep!  That's terrible to hear about your mishap!  DOh!  Least you didn't snap a tibia or something worse!  I know you can fix that minor stuff in an afternoon easy.

Work progress,...I uhhh,...well,....errr,....actually I moved out of my garage 'shop' and into another garage but haven't gotten everything settled to where I can do good work yet.  It's covered up, just waiting.

Ryot, I figured eventually work something out.  I wanted to get it roadworthy and riding and then move to a new phase.  When you first got your f3 I was really interested in what you had to say about it.  Maybe update your old post (http://gstwins.com/gsboard/index.php?topic=61774.msg719193#msg719193) with a review?  I'd sure like to read it.  :thumb:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Tombstones81 on December 28, 2012, 09:40:27 PM
Def got some skills man!

WOW to.... friggin ALL of it! hahaha  :thumb:

Last time I checked this is when you finished it with the previous motor.

Didnt expect ya to keep going Way beyond that!  :bowdown:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: xunedeinx on January 07, 2013, 10:50:42 PM
MOAR UPDATES!!!!!!!!!
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on June 13, 2013, 02:59:59 PM
(http://www.die-space.com/Images/Horror/Horror-Movie-Clips/images/Zombie-Rising.gif)

getting things set up again,....took a look trying to figure out where I left off yesterday,...wiring,...weee fun

(https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-frc3/992843_10201365977374690_1089280161_n.jpg)
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Big Rich on June 13, 2013, 11:33:00 PM
Glad to hear you're back at it Cbr.

The only good thing about doing wiring is that once it's done (properly), you don't have to worry about it for years.....
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on June 18, 2013, 06:37:14 PM
Thanks Big Rich!  Hope things are going good for you, by the way!

Finished my chop on the battery box to hold the electronics and got it set up.  Wiring away,....but saw this on cf and still undecided on my eventual tank.  Would love to weld something up that I could say I made myself like this guy is doing.

(http://i574.photobucket.com/albums/ss187/CamBandit17/20130526_212815_zps0739c7f5.jpg)
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Big Rich on June 18, 2013, 08:46:29 PM
Nice! A friend of mine started welding up a custom tank for a GS500 frame. I need to find out how far along he is on that.....
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on August 01, 2013, 09:44:26 AM
Yeah man, back from the dead, keep it up!  :thumb:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on August 15, 2013, 08:06:50 PM
Dunno if it's ok to tease with pics of (only) 600ccm engine, since your project ventured to 900, but I'll give it a go anyway. 8)

Sent from my toilet seat using HTC FartPhone



[attachment deleted by admin]
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: jacob92icu on August 16, 2013, 10:47:22 PM
Wow thats awesome! I really wanna see this bike completed haha.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on March 25, 2014, 02:27:46 PM
"Warning: this topic has not been posted in for at least 120 days."
(http://i.imgur.com/Mr5G82o.gif)

So jac told me gtf to work.  Worked on a few other projects blah blah blah,...recently finished this one,....

(https://scontent-b-dfw.xx.fbcdn.net/hphotos-prn2/t31.0-8/1780259_10203507995723810_1319127773_o.jpg)

fuel injection is badass.  FI WIN.  Anyways, have an old 77 kz1000 that I am itching to start but my old project gs is sitting there under a sheet and so much closer to being finished.

(https://scontent-b-dfw.xx.fbcdn.net/hphotos-prn1/t1.0-9/r270/604064_10203507995803812_1467214308_n.jpg)

Stuck on wiring.  I mapped it out to figure out what I lost since moving twice and almost have everything sorted.

(https://scontent-a-dfw.xx.fbcdn.net/hphotos-prn1/t31.0-8/1980126_10203507996083819_793234619_o.jpg)

Right hand controls had held me up in my brain, because rewiring another control to fit the 929 harness seemed daunting.  Praise God 95 cbr control was almost exactly the same!  Woot

(https://scontent-a-dfw.xx.fbcdn.net/hphotos-ash3/t31.0-8/10010078_10203507996283824_107466701_o.jpg)

Really want to get the old girl wrapped up.  Plan to cut that boeing 747 a**end off and make a stubby tail eventually but first I want to get it running and tuned.  An hour a day adds up to 5 hours of work at the end of the week plus time on the weekends!  DW.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: jacob92icu on March 25, 2014, 08:53:43 PM
Better pictures NAO!  :tongue2:

This is so cool haha. Its a 929 motor now that you are swapping? Thats going to be insane! Haha. See I told you I was interested in the thread, I was the last one too post before it died!
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on March 26, 2014, 03:23:35 PM
(https://scontent-a-dfw.xx.fbcdn.net/hphotos-prn2/t31.0-8/1965556_10203514786493575_52405370_o.jpg)

worked on getting my right side controls set up, 600 set up, broke 929, and 95 cbr I'm switching over to.  Oh and yes jac, is a 929rr engine.  I think it should have around 128hp. 

(https://scontent-a-dfw.xx.fbcdn.net/hphotos-prn1/t31.0-8/1961956_10203514786453574_279255600_o.jpg)

test fitting, I think this'll work

(https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-prn2/t31.0-8/1921236_10203514786533576_1245974024_o.jpg)

sure wanted to stay home today and work on it all day,...
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: jacob92icu on March 26, 2014, 06:51:32 PM
Oh my goodness... That is going to be complete insanity on the little gs frame. I wish i was there to help you finish it lol. Your going to upgrade the suspension and braking as well I'm guessing?
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on March 26, 2014, 07:48:16 PM
Eventually I'm sure!  My pipes are pretty low up front,....will have to do something with suspension.  Really just want to get it running and then start polishing it off.  Buddha told me before I started this that I'd have to reinforce or risk whopping the frame, so someday I'll have to cover that step.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: steezin_and_wheezin on March 26, 2014, 08:14:53 PM
Its coming along!!
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on March 27, 2014, 02:17:19 PM
Thanks steez,....trying to get something done every day now.  Didn't have too much time last night.  Got out the blowgun and blew out all the dust and cobwebs.  Looking over the harness as to what I still need.  Spent most of my time in the attic digging for a clutch cable mount.  I know it's here somewhere.  Found all kinds of other crap I didn't know I had.  Found gs rectifier for that guy who can't afford one,....if he ever pms me.  Need to write out a plan of attack and check them off as I go.

(https://scontent-b-dfw.xx.fbcdn.net/hphotos-prn2/t31.0-8/1277760_10203522055635299_602233726_o.jpg)

Can't wait to cut the a** off and re-do it.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: jacob92icu on March 27, 2014, 08:56:56 PM
Man this is crazy. Ride it over to my place in like 2 seconds warp speed and let me ride it around when you are done :)
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on March 28, 2014, 03:08:12 PM
Yesterday, wrote down short term goals so i don't sit there for 30 minutes staring at it before I begin figuring out what to do each day (left control switch, ignition, kickstand, chain).   Got some kickstands down and looked for the 'easy' button.
Gs and cbr 95,...
(https://scontent-a-dfw.xx.fbcdn.net/hphotos-prn1/t31.0-8/857233_10203528931087181_820308593_o.jpg)

you can see where it was before i hacked it off, no way it would work in that location now
(https://scontent-a-dfw.xx.fbcdn.net/hphotos-ash3/t31.0-8/1926012_10203528931167183_1855446418_o.jpg)

cbr
(https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-frc1/t31.0-8/1836853_10203528931127182_255031732_o.jpg)

After messing with these for too long.  Grabbed one off a scooter and played with it.  Maybe where the center stand bolted in,...I could make a little bracket and mount it there.  It is short, light and I think it'd work.  I want to put the kickstand back on so I can move it around without using the rear stand.

Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on March 28, 2014, 03:32:33 PM
anybody know how to resize pics in html,...... :dunno_black:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: steezin_and_wheezin on March 28, 2014, 03:51:01 PM
Guessing you had to cut the original GS kickstand spot off to fit the engine?

Image resizing;
[img width=XX]http://url[/img ] - XX=desired width and w/o the last space in img bracket. Like so;

(https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-frc1/t31.0-8/1836853_10203528931127182_255031732_o.jpg)
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on March 28, 2014, 04:07:44 PM
Finally dude, eppur si muove!

:D:D:D:D

Sent from my toilet seat using HTC FartPhone

Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: jacob92icu on March 28, 2014, 06:37:11 PM
I am already salivating over the future video of this thing running!

Looks so awesome. And I cant wait to see full pictures of everything all back together with that huge engine in that tiny space haha.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on March 28, 2014, 06:44:16 PM
 :woohoo: :bowdown: steez,....couldnt get that out of cods or janx!  thanks,..really helps!

Hey Shep!  Good to hear from you!  But shhhhh!  You just need to post more pics,......you can't sit up there on 'engine swap king' throne forever haha  :icon_razz:

jac thanks for the boost, really feel inspired to get this done.  kickstand, control & ignition wiring, chain,....i know some vacuum hoses are crapped out, leaving airbox like it is for now even though it weighs as much as a small tank, will get the gas tank down later and see how it looks inside,.....i'm sure there are more wiring oddballs to tie up, probably have to clean throttle bodies out,......and then may be able to test fire.  fingers crossed.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: yamahonkawazuki on March 28, 2014, 06:52:34 PM
Cleaning on throttle bodies is a given :)
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on March 28, 2014, 07:51:22 PM
Oh well... I got so used to bike, that I don't bother taking pictures any more, so here are a couple of older ones...

Sent from my toilet seat using HTC FartPhone



[attachment deleted by admin]
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on March 28, 2014, 08:52:16 PM
Shep you ever ride a stock GS since you succeeded in transplanting the 600?  I figure if you rode a stock GS you would keep thinking 'wtf is wrong with this thing?!'  :icon_mrgreen:  Spanktastic pics by the way,...thanks for sharing!
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on March 28, 2014, 09:53:44 PM
Actually, last year I've changed the fork seals on a friend's GS, and while at it, I advanced it's ignition timing a couple of degrees, just for fun.

After that, I took it for a spin.... and scared myself to death.

The darn thing takes ages to accelerate, even longer to stop, and the ride reminds me of a waterbed, all squishy and mushy...

Sorry to all purists here, but no more stock GS for me, ever.

;D


Sent from my toilet seat using HTC FartPhone

Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: jacob92icu on March 28, 2014, 11:04:45 PM
Actually, last year I've changed the fork seals on a friend's GS, and while at it, I advanced it's ignition timing a couple of degrees, just for fun.

After that, I took it for a spin.... and scared myself to death.

The darn thing takes ages to accelerate, even longer to stop, and the ride reminds me of a waterbed, all squishy and mushy...

Sorry to all purists here, but no more stock GS for me, ever.

;D


Sent from my toilet seat using HTC FartPhone

Hahaha no offence taken here. After having my cbr I took Adidasguys "Suzi" to grab some stuff from Aurora Suzuki and felt like i was riding some kind of electric bicycle lololol
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: jacob92icu on March 28, 2014, 11:08:04 PM
Btw Shepa,

That is by far the cleanest motor swap on a GS I have ever seen... Also, did you go with a katana front end as well? Would have been so sick to to throw a USD front end on there lol.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on March 29, 2014, 02:53:03 PM
Nope, standard GS front end, but with two right-side lower legs/tubes, for dual brake caliper mounting.

I have a Fazer600 front forks (with Ohlins springs and emulators) in my basement, but I'm not too eager for swapping because my dual caliper f.e. was a project of it's own, so I'm kinda proud of it, and love to explain to fellow riders how I made it.

If I do however install the Fazer forks, I'll combine them with gsxr lower tubes, so I can install 4-piston Nissin calipers I also have. :))

Sent from my toilet seat using HTC FartPhone

Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: jacob92icu on March 30, 2014, 03:13:14 AM
Nope, standard GS front end, but with two right-side lower legs/tubes, for dual brake caliper mounting.

I have a Fazer600 front forks (with Ohlins springs and emulators) in my basement, but I'm not too eager for swapping because my dual caliper f.e. was a project of it's own, so I'm kinda proud of it, and love to explain to fellow riders how I made it.

If I do however install the Fazer forks, I'll combine them with gsxr lower tubes, so I can install 4-piston Nissin calipers I also have. :))

Sent from my toilet seat using HTC FartPhone

Wow innovative indeed. How easy was that swap? Simply turn the fork tube around and bolt it all back in??
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Big Rich on March 30, 2014, 04:23:47 AM
Simply turning a right fork around and mounting on the left side would leave the caliper on the front side......and Sherpa's caliper is behind the fork. C'mon Sherpa, spill the beans! Did you have caliper mounts Tig welded onto the leg?
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: jacob92icu on March 30, 2014, 05:08:02 AM
I feel like you could just leave the fork with the mount pointed backwards, since threads are threads and it doesnt matter which side the caliper bolts thread in from, so pretty much he just has two regular right forks both facing the same way. I believe thats how he has it now that I think about it. I could just be drunk though :cheers:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on March 30, 2014, 06:14:34 AM
Correct! ;)
But if you just put right fork leg on the left side, the fork brace mounting points will be facing outwards, so you need to cut them off and weld them on the inside of the fork leg.
Then you need two washers to bring the caliper in line with the disc (rotor).
And ofcourse, you need a left caliper.

I've used a V-Strom calipers, but almost any Suzuki 2-piston calipers would fit (Bandit, GSR, Katana)...

I can take a few close up photos, so you'll see how simple it actualy is.

Here are the two I took back in 2009 while doing the mod.


Sent from my toilet seat using HTC FartPhone


[attachment deleted by admin]
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Big Rich on March 30, 2014, 06:23:09 AM
Good thinking gents.

I've been working on older bikes for far too long - and flipping a fork for the brake mount is more complicated.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: steezin_and_wheezin on April 02, 2014, 08:29:57 PM
Putting some wind in your sails!! Post up your plan of attack/ToDo list so we can keep bugging you until you've checked them all off :cheers:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on April 02, 2014, 08:55:02 PM
(http://www.closets2you.com/wp-content/uploads/2012/09/shoe-storage.jpg)
#1 Finish wife's closet
(http://media.tumblr.com/tumblr_lr87hulAmI1qaljwj.gif)
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: jacob92icu on April 08, 2014, 01:12:19 AM
Hahaha thats some good stuff... She cant buy her own clothes??  :dunno_black:  :cookoo:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: steezin_and_wheezin on April 08, 2014, 12:45:10 PM
Haha always on the clutch with images/gifs! Best of luck with the wifey and her "gear"
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on April 08, 2014, 01:46:24 PM
Hahaha thats some good stuff... She cant buy her own clothes??  :dunno_black:  :cookoo:
:cookoo: She can handle that just fine Jac!  NO problem with that!
(http://www.girlsclothingdirect.com/wp-content/uploads/shopping.gif)

Which reminds me of,...
(http://englishwithatwist.com/wp-content/uploads/2014/04/Blog_women-v-men-shopping.gif)

I'm building shoe shelves, purse shelves, whatever else she wants to put on them, shelves, and everything else that will make her feel good in her closet.  I do understand the concept though.  Same as me in the garage, wanting all my crap organized, where I can see it and ready to do work.

-Thanks Steez!  Almost done and back to GS,....my goal is finish it by end of summer.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on April 08, 2014, 02:45:03 PM
-Thanks Steez!  Almost done and back to GS,....my goal is finish it by end of summer.
This year?

C'mon dude, by the time you finish it, people will be teleporting around instead of riding.

Enough of the chit-chat and get on with it!!!

>:(





;D

Sent from my toilet seat using HTC FartPhone

Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on April 10, 2014, 03:59:17 PM
Ordered a left side control so I don't have to rewire anything. :cheers:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: jacob92icu on April 12, 2014, 07:02:20 AM
Thats the best feeling ever! Lets just hope it is true!! Haha
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on May 19, 2014, 02:51:23 PM
wooo hooo did,....2 minutes of work,....

(https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-prn2/t1.0-9/10306721_10203915725436798_3774142962690782005_n.jpg)

(https://scontent-b-dfw.xx.fbcdn.net/hphotos-frc3/t1.0-9/10306256_10203915725636803_1050815311602652631_n.jpg)

as SOON as I finish this 4 wheeler project (https://scontent-b-dfw.xx.fbcdn.net/hphotos-xap1/t1.0-9/10367181_10203915750197417_5659915937404581264_n.jpg),......

............................................................................
worked on my kickstand after my wife ran into the bike with her car and knocked it over in the garage.  Not that having a kickstand would have kept it from getting knocked over.  Don't see anything really messed up.  It fell on my blower fan which was crushed.  Thanks babe!
............................................................................
2 minutes more work,....
brilliant idea to just put the centerstand back on >ding<
(https://scontent-b-dfw.xx.fbcdn.net/hphotos-xpf1/t1.0-9/10360904_10203995993643453_8042705578635381756_n.jpg)

(https://scontent-a-dfw.xx.fbcdn.net/hphotos-xap1/t1.0-9/10359510_10203995992603427_3247350829027506149_n.jpg)
got tired of screwing around trying to make a new side stand.  First attempt at side stand close but needs some tweaking and I want to move on.
...........................................................................
getting good at this two minutes of work thing,...
(https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-xpf1/t1.0-9/10441524_10204028051724885_6122250062433928141_n.jpg)
put battery, ah looks like battery in battery tray,......also started wrapping up harness to see wth I am missing,...
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: ShowBizWolf on September 16, 2014, 08:00:34 PM
cbr, anything new to report on this awesome project?
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: jacob92icu on September 17, 2014, 01:54:46 AM
Yea man, hurry up and finish this darn thing slow poke. ;)

But really though, i want to see it finished.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Donnie on September 17, 2014, 03:06:56 AM
Now I think I know what my next project will be .... Just need a donor bike to start with. A Susuki 600 r motor in a Gs500f frame could be alot of fun...  :icon_twisted:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on September 18, 2014, 06:56:06 PM
(http://belieber.files.wordpress.com/2011/02/squirrel-up-dog-gif.gif)

thanks for asking Show,...I did a couple 4 wheelers and then got distracted by another project similar to steez's Low expectation teaser,....doh


Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: iamhiding on December 20, 2015, 05:59:55 PM
fuuuuucking hell... love my gs, love my cbr f3. what a swap! personally id have looked at using a big twin like a vtr, trx or tl motor, maybe even ventured into the realms of v4 with a vfr 750 motor (something I've been considering actually) rather than completely lose the twin sound / characteristics with an inline 4. yeah i think the thread resurrection is excusable here! just WAAAAW! shame a lot of the pics don't work anymore. think this just took 1st place in my interesting gs build list over the carbon tanked / supercharged one that never got finished over on customfigters.

any idea if this beastie is still going, its been further built or what the story is?

the early blade engine is swappable into the f2/f3 frame so i don't see why its not feasible in a gs frame. i don't think its a great swap on the 600 frame as all you end up with is a heavier blade... but yeah it should work on a gs frame lolz
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on December 22, 2015, 05:33:27 PM
hola iam,.....it's just sitting in the garage under a bike cover.  I haven't given up on it.  I started building a chevelle and put all bikes (sacrilege i know!) on the backburner.  When I get this turd chevelle rolling I want to get back on it and finish it.  Shep finished his in flying style before I was even close.  I kept having carb problems with the 600 set up and figured why stop, why not try to make the 929 engine with fi fit.  Got all that done and wiring quagmired me and KZ, and then chevelle so, uhm yea.  No excuses right!  Well thanks for zombiethread resurrection,... :icon_mrgreen:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: iamhiding on December 22, 2015, 06:05:45 PM
hola iam,.....it's just sitting in the garage under a bike cover.  I haven't given up on it.  I started building a chevelle and put all bikes (sacrilege i know!) on the backburner.  When I get this turd chevelle rolling I want to get back on it and finish it.  Shep finished his in flying style before I was even close.  I kept having carb problems with the 600 set up and figured why stop, why not try to make the 929 engine with fi fit.  Got all that done and wiring quagmired me and KZ, and then chevelle so, uhm yea.  No excuses right!  Well thanks for zombiethread resurrection,... :icon_mrgreen:

hey hey cbr! you sir are epic! :icon_mrgreen: :cheers: haha glad to hear it and yourself are still around. must be some sleeper... was going to ask how it was to ride but you won't ''really'' know if the carbs weren't quite right, those motors are epic in the cbr though, i'll be putting 38mm blade carbs into the f3 build sometime next year and I'm already running a 929 front end actually, the 330mm disks are nuts.

so... wait, you've actually squeezed the 929 engine in already? :confused: that is maaaaadness. i think some pics might be in order when you've got some spare time :thumb:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on December 22, 2015, 07:06:53 PM
Shep is epic :bowdown:,....he got his rolling and going.  I just got a big puttering paperweight.  heheh  :icon_lol:  Still though i learned alot and had fun doing it.  The 929 engine is already in there.  I was routing wiring and complaining about the tail last as far as I remember.  Talking about it makes me want to start messing with it again. :cheers: No no must finish chevelle first.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Daeouse on December 23, 2015, 08:40:11 PM
I'm absurdly late to this topic, and I wish the old pics still worked!!! The one completed pic with the 600 engine looked amazing! Can you post up some of those pics up again? Pretty please? With bacon sprinkles on top? :wink:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on December 24, 2015, 03:17:24 PM
I saved some of Shep's pictures somewhere.  I have to figure out where I put them. :embarassed:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: iamhiding on December 25, 2015, 05:38:08 PM
you're both a couple of nutters if you ask me ;) haha I'm actually so pumped about this, its an utterly ridiculous swap.

have to ask are you planning on keeping it sleeperish in stock trim or are you going to get a decent set of forks and swingarm on it and make something mega?

Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on December 29, 2015, 08:25:40 PM
I think it'll just come out however it comes out.  Definitely not stock looking.  I was thinking last night while welding on the floor pans that I can really do a better job fabbing on the bike since I have better tools to use.  My wife actually offered 'her' side of the garage and to leave her car outside so I could kickstart the project again.  :icon_mrgreen:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: steezin_and_wheezin on December 31, 2015, 02:50:46 PM
Haha sounds like my furnace. Too many irons in there!! Stoked to see there's still hope to have her up and running. I'll have to dig back through and catch up. All I have to say is, bring back that sled headlight!! Loved the look of it

Good luck on the Chevelle, I'm currently swapping out my old subaru with a WRX power and drive train(like we didn't already have 7000 projects to be had). You have a project thread somewhere for your car?
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on January 11, 2016, 09:01:22 PM
Nothing on Chevelle steez.  Just working on it when I can.  My son went and bought a vstar 1100 and I took it out yesterday.  Took me hours to fall asleep last night fiddling ideas on the bike back n forth on the strings of my pea brain.  Dam it was fun to go ride. 
(http://www.durhamcollege.ca/wp-content/themes/dc/pqapa/images/pqapa-head-gears.gif)
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on January 12, 2016, 05:19:41 PM
Nothing much on this side of the Atlantic either.
The front end mod's been postponed once again  :icon_mrgreen: :icon_mrgreen: :icon_mrgreen: due to an cafe racer sideproject for a friend, but that's another story.

Just a couple of pics from couple o' days ago:

(http://imagizer.imageshack.us/v2/1024x768q90/905/MWqwOW.jpg) (http://imageshack.com/f/p5MWqwOWj)
(http://imagizer.imageshack.us/v2/1024x768q90/903/JrJOpC.jpg) (http://imageshack.com/f/p3JrJOpCj)
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on January 13, 2016, 07:58:44 PM
 :bowdown:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on April 09, 2016, 08:28:57 PM
Got the new muffler for 43€ at AliExpress, so why not take the picture of it, right?

(http://uploads.tapatalk-cdn.com/20160409/6760bc3dd44e9317b9cfab952968eb54.jpg)

And... installed a CBR600 rear shock.
You can't see it, but it's there, and I must say, way better than SV650's.

(http://uploads.tapatalk-cdn.com/20160409/bc5557c35ee976c20c6d392fac83d2de.jpg)

The photos are in B/W cause the bike's way too dirty for colour, LOL.

And... got myself a GoPro Hero4 Session, so hopefuly, I'll make some clips eventualy, at least for the project's 5th year anniversary.

 ;D

Sent from my toilet seat using HTC FartPhone

Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on April 12, 2016, 04:50:22 PM
oooh ahhhhh  :thumb:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on September 14, 2017, 06:31:09 PM
(https://scontent-lax3-2.xx.fbcdn.net/v/t1.0-9/16712012_10212240694235815_498822230459079903_n.jpg?oh=df7cd58ec577daadf1fada77c8f44e07&oe=5A18A776)

(https://scontent-lax3-2.xx.fbcdn.net/v/t1.0-9/16807275_10212276549532175_710648758943524485_n.jpg?oh=d77de956d79b4e9392a70f30dac07e0f&oe=5A5BA559)

(https://scontent-lax3-2.xx.fbcdn.net/v/t1.0-9/16649343_10212240696355868_2686769726058204147_n.jpg?oh=d83ee2ac0ae53e66e01a9aaf49be67e0&oe=5A43300D)

(https://scontent-lax3-2.xx.fbcdn.net/v/t1.0-9/16711926_10212256212503762_7363565744362813180_n.jpg?oh=3cb4fa7fb3ab6df50aea1981ba1e7eda&oe=5A132239)

(https://scontent-lax3-2.xx.fbcdn.net/v/t1.0-9/16806929_10212256212543763_3273231033381758437_n.jpg?oh=e0dcf006d13778873d6beedd8da2f15a&oe=5A48708B)

(https://scontent-lax3-2.xx.fbcdn.net/v/t1.0-9/16832349_10212276549492174_2856027008303024272_n.jpg?oh=0a5d2803804347093c1ae736dbdc575f&oe=5A168A30)

(https://scontent-lax3-2.xx.fbcdn.net/v/t1.0-9/16830949_10212276549452173_7348895728659405439_n.jpg?oh=8726bf88729e4b40a3ad01fbd3ac20d8&oe=5A13FC03)

(https://scontent-lax3-2.xx.fbcdn.net/v/t1.0-9/16807230_10212280679955433_3683764597265003011_n.jpg?oh=c3da1cf811cd21645488859e79a46187&oe=5A5204A9)

(https://scontent-lax3-2.xx.fbcdn.net/v/t1.0-9/16831915_10212280680075436_5729182152823367348_n.jpg?oh=509ae939db54a574cf708840ccab6d16&oe=5A59A6DE)

(https://scontent-lax3-2.xx.fbcdn.net/v/t1.0-9/16807337_10212280680235440_4354968356274697242_n.jpg?oh=8b260af013b807e5f42da8b417ec5a93&oe=5A4D8D9E)

Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on September 14, 2017, 06:34:31 PM
(https://scontent-lax3-2.xx.fbcdn.net/v/t1.0-9/19959316_10213741457673963_502072143952207877_n.jpg?oh=5a2f034c8d0dc07560ee848b66195eec&oe=5A1655A6)

(https://scontent-lax3-2.xx.fbcdn.net/v/t1.0-9/20264809_10213866288914666_4970901295273019015_n.jpg?oh=9cf0ad5b615164015a6eb6fd2bcb8031&oe=5A43747B)

(https://scontent-lax3-2.xx.fbcdn.net/v/t1.0-9/20246057_10213866289874690_6721824171998146049_n.jpg?oh=a8531b2d82565d5cd45f48af302deef7&oe=5A42CA5C)

(https://scontent-lax3-2.xx.fbcdn.net/v/t1.0-9/20264563_10213866289354677_256751638047833746_n.jpg?oh=637566e7e628ce525c361fba61aacf00&oe=5A5FCB03)

(https://scontent-lax3-2.xx.fbcdn.net/v/t1.0-9/20374703_10213876925660578_2360720972436494365_n.jpg?oh=36c86569127834c41302d70454604930&oe=5A5F6C23)

(https://scontent-lax3-2.xx.fbcdn.net/v/t1.0-9/20246423_10213876925980586_8052067681476114633_n.jpg?oh=084b6b8fd5c5ac0c77f8f62aca4cd080&oe=5A17BAEB)

(https://scontent-lax3-2.xx.fbcdn.net/v/t1.0-9/21731332_10214307304939791_4249972902970050692_n.jpg?oh=2d9e6456ae41a461832298ef49d5ae75&oe=5A5DC2F6)

(https://scontent-lax3-2.xx.fbcdn.net/v/t1.0-9/21742960_10214307304739786_7021590041230428163_n.jpg?oh=7de49a084be027525dfba99f9a20ba44&oe=5A47332F)

(https://scontent-lax3-2.xx.fbcdn.net/v/t1.0-9/21739962_10214307305779812_4193836501745175829_n.jpg?oh=4481a2557062f9475928b872d95ef9a7&oe=5A50323C)

(https://scontent-lax3-2.xx.fbcdn.net/v/t1.0-9/21728486_10214307305299800_4077579634758843869_n.jpg?oh=ca2e7e55f0897b2bf86eefb70e73fc11&oe=5A19B430)
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: steezin_and_wheezin on September 15, 2017, 02:18:43 PM
Happiness Level = A dancing Ron Swanson
(http://i287.photobucket.com/albums/ll129/steezin_and_wheezin/Ron%20Swanson_zps98upmkdu.gif)
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: ShowBizWolf on September 15, 2017, 06:11:43 PM
YASSSSSSS this is great!!!!! :woohoo:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on September 18, 2017, 08:33:04 PM
(https://image.ibb.co/koBzpc/21752466_10214345427692836_6567351792119725447_n.jpg)

(https://image.ibb.co/dPwtFH/21558979_10214345428812864_1235236128421338026_n.jpg)
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: ShowBizWolf on September 18, 2017, 10:04:00 PM
In the first pic... those legs tho...  :thumb: :thumb: :thumb:

Bike is lookin' GOOD cbr 8)
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on September 27, 2017, 12:55:10 PM
First ride last night. Well more like first putt putt. I think the battlecow would've taken me out. Up and down the street a bit looking for issues. First and foremost I think I knocked a vacuum line off so need to find that. It was running like a line was disconnected. Nevertheless making progress and first ride is a good moment. :bstar:
Video after I find that leak,.....
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Big Rich on September 27, 2017, 06:14:58 PM
 :thumb:

That first ride is always an awesome experience..... even when there's problems to be sorted out. And they get better & better afterwards!
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on October 02, 2017, 02:13:32 PM
Changed out all the vac lines and running nicely now.  Didn't have time to make video but hopefully tonight. :icon_mrgreen:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on October 02, 2017, 02:53:41 PM
Finally! For a year or two, I was affraid you gave up.

😂😂😂

Sent from my toilet seat using HTC FartPhone

Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: steezin_and_wheezin on October 02, 2017, 05:21:19 PM
(http://i287.photobucket.com/albums/ll129/steezin_and_wheezin/smilin/giphy_zpsrjz9ljnk.gif)
(http://i287.photobucket.com/albums/ll129/steezin_and_wheezin/smilin/motorcycle17_zps50ffb03a.gif) :cheers:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on October 03, 2017, 02:11:52 PM
U hilarious steez :icon_razz:

It was getting dark and this is mainly to see my chain alignment and how it looks in motion.  I think it's ok.  Still alot to sew up, connectors hanging, need to rework the tail or try a new idea, turn signals, show's hugger idea, front brake is completely useless-waiting on replacement, shifter is janky and backwards, install radiator temp sensor, some welding reinforcement, other crap I'm sure.  Hopefully it'll come together smoothly and I can make it a daily driver.  Open header sounds awful by the way hahah


please flame me for riding in shorts 8)
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: iamhiding on October 09, 2017, 01:08:39 PM
CBR! you ridiculous human being  :icon_lol: :icon_mrgreen:  :cheers:

can't believe it's coming together now. usually i hate side mounted radiators like the vtr with naked bikes but with how far the engine protrudes, then the radiators as well it just looks bat shaZam! crazy wide and mean. that's a proper mental looking machine man, cant wait to see some more angles of it in the light.

it's a shame most of the thread is dead links now, hope you've got some extra bracing on that frame  :icon_twisted:  :thumb:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on October 09, 2017, 03:49:51 PM
ha iam!!  That was only way I could figure to get them on there!  First time they heated up was pretty cool moment for me :icon_mrgreen: tbh.  Right now, waiting on gs500f tail cause I hate how the 600rr tail looks.  I figure returning to gs lineage would be best.  I hear buddha snickering somewhere as I'm typing that.  lol  Still have bunch of small things to do.  I think the frame is ok.  Well I'm hoping it is!  Installed inline temp sensor so I need to take it out to see if it's working right,...

,...maybe I can fix some of those old pic links,...

Where's some videos Shep?!  At least a pic or something! :icon_razz:  Couldn't give up on it.  It's just been sitting there waiting,...  trying to get it sewed up and lane splitting asap!
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Shepa on October 09, 2017, 07:16:57 PM
Well, I'm sad to say it, but I've sold my bike couple of days ago, so I could buy something else.
It's been fun 6 years since the engine swap, and (only) 36000 kms traveled, but I guess it was time to let go.
I wish I could afford to keep it together with a new bike, but I couldn't.
So... only memories, photos, and couple of videoclips taken during the swap process remain.
😭😭😭😭😭

Sent from my toilet seat using HTC FartPhone
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on October 24, 2017, 02:46:22 PM
Playing with tail(s).  I hate how the huge tail looks that I put on it, so thought to go back to gs origins.

(https://scontent.fhou1-2.fna.fbcdn.net/v/t1.0-9/22814098_10214633862343522_6336369584493673795_n.jpg?oh=d59b3988aeafbfe10fdfc6de48455e8a&oe=5AB040A8)

unfortunately that looks worse.  So, had a later and smaller rr tail and,...

(https://image.ibb.co/e8QvvH/22730212_10214633862183518_6022334173677869200_n.jpg)

looks a little better.  I 'think' I'll go with this.  Need to fab some mounts and then some side covers to hide the frame & wiring.  Still, I have the seat and tail cover already.  Sorry pic is blurry, my phone is slowly crapping out.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: The fink on October 27, 2017, 10:39:03 AM
Awesome!  :cheers:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: iamhiding on October 27, 2017, 12:15:40 PM
 :cheers: :thumb: awesome!

so what are you're plans for the forks, shock and rear wheel?

i dont mind that 600rr tail, it does look a bit too long though, i cant tell in the pics is that the 04ish tail with the vents either side of the rider seat or the rr7 and later without?

the gs has a good looking seat i reckon but the plastics are a bit... mehh.

i dont know what kind of look you're going for but have you considered a rs125/rs250 race tail? theres a couple of variations but they're awfully good looking, quite short, sharp and simple. a smaller tail is going to open the gap around the rear wheel, visually emphasise the massive motor and... front end if you put some 929 upside downies on or something to that effect  :thumb:

this build is just too mental!  :cheers: :icon_eek: love it.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: J_Walker on October 27, 2017, 06:48:25 PM
the 04 tail is the first one with the "vents"

I vote cut off the rear subframe all together and sit on the gas tank the whole time...  :icon_twisted:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: Endopotential on October 30, 2017, 05:28:42 PM
or forget about tail plastics altogether, as I did on mine  :D
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: ShowBizWolf on October 30, 2017, 08:36:10 PM
I'm kinda diggin' that idea Endo!
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: iamhiding on October 31, 2017, 10:30:26 PM
the 04 tail is the first one with the "vents"

I vote cut off the rear subframe all together and sit on the gas tank the whole time...  :icon_twisted:

nope, rr3 to rr6 have vents in the side, rr5 and rr6 have vents and keyholes to the rear of the riders seat but the earlier ones dont. rr7 onwards doesn't have vents, it's physically shorter(finishes half way along the seat) and retains the key hole. to answer my own question it'll be one of the earlier ones in the pic :icon_lol:

or forget about tail plastics altogether, as I did on mine  :D

i'm with either of those ideas!  :icon_twisted: :cheers: less weight = more fasterererer  :icon_lol: or cut the lot off and just stand on the pegs  :cheers:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on November 06, 2017, 10:44:26 PM
That's good info iam!  Original tail didn't have the keyhole but this one does.  I couldn't figure out why I had two different tails from 'supposedly' the same model.  Either way, I like the shorter one w/ keyhole better now.

I'd like to do a swingarm swap with bigger tire.  Jim said he has a deal for me on an extended s/a so might try that.  Not really sure yet.  Fork swap would be great too but it'll be down the line.

Endo, I thought about it but I need a place for the battery.  The way the fuel pump hangs down, plus wiring, I don't have good room to get a battery in there too.  Using the tail gives me plenty of room.

Reworking the tail and cut that mess off to redo it.  Better lines and actually straight this time.  Funny how that is when you look back at old work.  Thinking wth was I doing,...haha

(https://image.ibb.co/d49G2x/triagnle6.jpg)

Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: ShowBizWolf on November 06, 2017, 11:38:50 PM
Funny how that is when you look back at old work.  Thinking wth was I doing,...haha
 

Boy, I've certainly been there before :oops: :cookoo: :icon_rolleyes:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on November 07, 2017, 03:03:10 PM
triangles and more triangles,...

(https://image.ibb.co/jJcfUc/triangle5.jpg)

(https://image.ibb.co/gf179c/triangle4.jpg)

(https://image.ibb.co/m9VdFH/triangle1.jpg)

(https://image.ibb.co/jWjihx/triangle2.jpg)

(https://image.ibb.co/ibXsaH/triangle3.jpg)






Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on January 02, 2018, 09:10:18 PM
1/2,...chasing sensor malfunctions.  IAT and MAP giving me codes,.... :technical:

1/4,... swapped out iat sensor, checked map connections, reset memory and cranked it up.  Started well, sunk to idle and stalled.  Adjusted idle, restart and gassed it a bit and it held idle.  Few times like that and nice idle now.  Sweet.  On to more tidbits,...
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: ShowBizWolf on January 05, 2018, 09:40:32 PM
Awesommmeeeeee  :icon_mrgreen: :icon_mrgreen: :icon_mrgreen:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: ajensen on January 06, 2018, 04:41:00 AM
Great to see Showbiz back after a couple of weeks--she's my hero.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on January 08, 2018, 02:45:10 PM
Mine too!  Look at that crazy tmnt's creation she fabbed up!  Was wondering where she went to  :dunno_black:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: ShowBizWolf on January 09, 2018, 08:34:00 AM
Awe thanks you guys! :kiss3: I'm always lurking around :thumb: :-*

I hope to have some updates to my thread this year!
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: iamhiding on January 12, 2018, 01:38:41 PM
slow progress but you're getting there man.  :thumb: looking good
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on January 12, 2018, 02:52:18 PM
farging around with my radiator fan wiring.  Found that the fan isn't working so what little time Ive had, been tracing that.  My wife keeps asking me when I'm going to finish it.  I keep asking her when am I going to get some garage time,....

___________________________________________________________
Got fan wired in finally after putting too much time into that :technical:

Front brake sorted after two calipers changes and crappy master cylinder,.... still did a little victory jig on that one though :laugh:
___________________________________________________________

Wired in tail light signals and brake light weeeeee

____________________
Little more odds n ends. Wiring fun.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: ShowBizWolf on February 03, 2018, 12:59:59 AM
weeeeeee indeed!!!  :woohoo:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on March 15, 2018, 03:50:15 PM
(https://scontent.fhou1-2.fna.fbcdn.net/v/t1.0-9/29217011_10215860084558311_254063945671770112_n.jpg?oh=2377e46834c18677632b420309b73853&oe=5B3B4394)
jacking around with paint,...  Need show to school me on bandit hugger,... need to do seals & sonic springs,.... need battery,..... wish i could find one of addy's chainguards,..... little wiring clean up,..... go over everything, clean up a bit and im just going to ride it for awhile before doing anything else.  This was after ride around the neighborhood since it'd been sitting a few weeks.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: ShowBizWolf on March 16, 2018, 01:05:33 AM
I absolutely love the look of this.  Sooooooo tuff !!!

If you go with the Bandit 400 hugger, you won't need to track down onea those fancy chain guards cuz the hugger has the guard built in :thumb:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: ajensen on March 20, 2018, 10:23:13 PM
That is one bad motorcycle, sinister somehow.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: The Buddha on March 21, 2018, 12:11:47 AM
(https://scontent.fhou1-2.fna.fbcdn.net/v/t1.0-9/29217011_10215860084558311_254063945671770112_n.jpg?oh=2377e46834c18677632b420309b73853&oe=5B3B4394)
jacking around with paint,...  Need show to school me on bandit hugger,... need to do seals & sonic springs,.... need battery,..... wish i could find one of addy's chainguards,..... little wiring clean up,..... go over everything, clean up a bit and im just going to ride it for awhile before doing anything else.  This was after ride around the neighborhood since it'd been sitting a few weeks.

Hey .. is that a GS500 ???? I cant quite put my finger on it, but something is modified ...
Cool.
Buddha.
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on April 11, 2018, 03:05:22 PM
(https://image.ibb.co/ccjFPx/30582424_10216096639192029_8572110202843693056_n.jpg)
Got one done finally.  Took my time since this was my 1st one.  Sonic springs, new seals and fork oil.  Actually super easy to do.  Should knock the second one out in no time.

Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: ShowBizWolf on April 11, 2018, 08:13:14 PM
That's awesome!! What length did you cut the pvc spacer down to cbr?
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on May 16, 2018, 03:37:56 PM
(4-7/8 show!)

(https://image.ibb.co/irzQLd/IMAG6519.jpg)

(https://image.ibb.co/myUQLd/IMAG6524.jpg)

(https://image.ibb.co/nE6SYy/IMAG6522.jpg)

(https://image.ibb.co/dzKQLd/IMAG6523.jpg)

(https://image.ibb.co/mJY7Yy/IMAG6521.jpg)

Did some spraying and clear coating with spraymax 2k.  That stuff is amazing.  Dang bugs flew into my clear in a few spots so need to sand them out, cut and polish.  few more things and getting close to finishing, well finishing to where I can ride regularly before swingarm mods. :icon_razz:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: KHnTX on May 17, 2018, 06:17:28 AM
Very nice looking!

Sent from my ONEPLUS A3000 using Tapatalk

Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: ShowBizWolf on May 17, 2018, 07:35:35 AM
I absolutely love it!!! :-*
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: The fink on May 18, 2018, 06:07:40 AM
Hot damn! That looks awesome!!  :cheers:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on June 14, 2018, 02:41:00 PM
screwing around with bodywork here and there.  Finally sorted out the rear pillion cover mount for the most part.  Need to wet sand with 5000 grit, cut and polish,....eventually.
(https://image.ibb.co/mmhbkJ/IMAG6573.jpg)

fender mounts redone and seem ok.  Might be too close on rotor side.  May need an extra washer or two in there to give it more clearance.
(https://image.ibb.co/eTXyzd/IMAG6657.jpg)
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: ShowBizWolf on June 14, 2018, 04:48:51 PM
I love your updates!!! Woot toot :woohoo:
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on July 16, 2018, 08:33:50 PM
Been hating the round headlight so trying out a new one.

(https://image.ibb.co/gegRZJ/IMAG6748.jpg)

(https://image.ibb.co/mhwtEJ/IMAG6747.jpg)

This is just the bodywork for the light.  Need to clear it and get it ready to mount.  I think it goes better with the bike's lines than the round headlight. 

Thx show for your input too(https://www.motohouston.com/forums/images/smilies/secret.gif)
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: ShowBizWolf on July 16, 2018, 09:37:30 PM
You're quite welcome :-*
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: cbrfxr67 on August 13, 2018, 02:32:52 PM
(https://image.ibb.co/ciELY9/IMAG6876.jpg)

(https://preview.ibb.co/hYmZt9/IMAG6878.jpg)

(https://image.ibb.co/gRiQ0p/IMAG6880.jpg)

(https://image.ibb.co/jkO3mU/IMAG6881.jpg)

messing around with this headlight set up.  Maybe I need to move it back a little.  Any critics? :laugh:
I did take it out for a few passes and my forks with sonics springs are fookin amazing!  Bow and respect to Mr. Desmond!  My exhaust was scraping on turns and now it is GOOD.  Really happy with that.
Need to make some side panels, clean up, and,...I'm sure there'll be something else to do,...
Title: Re: 1996 GS500 Basket Case Build into a GS600R
Post by: ShowBizWolf on August 13, 2018, 10:33:25 PM
 :woohoo: That looks sooooooo good cbr!!!