That explains alot.The GS tank body is three pieces,two halves and a bottom, and probably Jig welded to boot.

Quote from: cbrfxr67 on July 26, 2011, 06:50:13 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...

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.

.........

Later on, you need to weld a couple of bolts on top of the box, for lid fixation.

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.

Quote from: cbrfxr67 on July 27, 2011, 12:52:51 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.

Drive down here to FL and ill do it for you.

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.

That thing would look good with a sporty muffler sticking out the back end of it.

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!!! 

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.

Quote from: cbrfxr67 on July 30, 2011, 08:04:50 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.

They look SCHAWEEEETT!

(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.

Quote from: cbrfxr67 on August 01, 2011, 06:56:45 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.

Heat up the header pipes with a torch, and bend it a few degrees.

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. 

shaZamming hot today

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.

Quote from: cbrfxr67 on August 09, 2011, 05:59:46 PM
Tonite, put in an hour to cleaning the carbs and started reassembly.  Carb cleaner stinks!

Dirty carbs stink even more!

anymore progress?

this thing is going to be a beast once its all buttoned up

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.

If this thing works out well, how much for a conversion?

I WANT ONE!

xune, you should just stuff a fat FI 900 in yours!  Oh and do a build thread with lots O' pictures!

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,.....

Quote from: cbrfxr67 on August 19, 2011, 02:54:51 PM
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!