Author Topic: 1996 GS500 Basket Case Build into a GS600R  (Read 133793 times)

Offline ben2go

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Re: 1996 GS500 Basket Case Build into a GS600RR
« Reply #200 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.
PICS are GONE never TO return.

Online Shepa

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Re: 1996 GS500 Basket Case Build into a GS600RR
« Reply #201 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...

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.
« Last Edit: July 27, 2011, 09:30:15 PM by Shepa »
There he goes. One of God's own prototypes.
A high-powered mutant of some kind never even considered for mass production.
Too weird to live, and too rare to die.

Offline cbrfxr67

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Re: 1996 GS500 Basket Case Build into a GS600RR
« Reply #202 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.
"Its something you take apart in 2-3 days and takes 10 years to go back together."
-buddha

Offline xunedeinx

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Re: 1996 GS500 Basket Case Build into a GS600RR
« Reply #203 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.

Offline cbrfxr67

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Re: 1996 GS500 Basket Case Build into a GS600RR
« Reply #204 on: July 28, 2011, 01:14:27 AM »

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.
"Its something you take apart in 2-3 days and takes 10 years to go back together."
-buddha

Offline xunedeinx

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Re: 1996 GS500 Basket Case Build into a GS600RR
« Reply #205 on: July 28, 2011, 01:59:56 AM »
That thing would look good with a sporty muffler sticking out the back end of it.

Offline Chancegs1996

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Re: 1996 GS500 Basket Case Build into a GS600RR
« Reply #206 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:

Offline cbrfxr67

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Re: 1996 GS500 Basket Case Build into a GS600RR
« Reply #207 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.
"Its something you take apart in 2-3 days and takes 10 years to go back together."
-buddha

Offline xunedeinx

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Re: 1996 GS500 Basket Case Build into a GS600RR
« Reply #208 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.


They look SCHAWEEEETT!

Offline cbrfxr67

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Re: 1996 GS500 Basket Case Build into a GS600RR
« Reply #209 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.
"Its something you take apart in 2-3 days and takes 10 years to go back together."
-buddha

Offline xunedeinx

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Re: 1996 GS500 Basket Case Build into a GS600RR
« Reply #210 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.


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

Offline cbrfxr67

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Re: 1996 GS500 Basket Case Build into a GS600R
« Reply #211 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. 

shaZamming hot today
"Its something you take apart in 2-3 days and takes 10 years to go back together."
-buddha

Offline cbrfxr67

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Re: 1996 GS500 Basket Case Build into a GS600R
« Reply #212 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.
« Last Edit: August 16, 2011, 01:27:16 AM by cbrfxr67 »
"Its something you take apart in 2-3 days and takes 10 years to go back together."
-buddha

Offline xunedeinx

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Re: 1996 GS500 Basket Case Build into a GS600R
« Reply #213 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!

Offline steezin_and_wheezin

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Re: 1996 GS500 Basket Case Build into a GS600R
« Reply #214 on: August 17, 2011, 07:21:41 PM »
anymore progress?

this thing is going to be a beast once its all buttoned up
if yer binders ain't squeakin, you ain't tweakin!

Offline cbrfxr67

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Re: 1996 GS500 Basket Case Build into a GS600R
« Reply #215 on: August 19, 2011, 02:51:08 PM »

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.
"Its something you take apart in 2-3 days and takes 10 years to go back together."
-buddha

Offline xunedeinx

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Re: 1996 GS500 Basket Case Build into a GS600R
« Reply #216 on: August 19, 2011, 08:42:37 PM »
If this thing works out well, how much for a conversion?

I WANT ONE!

Offline cbrfxr67

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Re: 1996 GS500 Basket Case Build into a GS600R
« Reply #217 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!
"Its something you take apart in 2-3 days and takes 10 years to go back together."
-buddha

Offline cbrfxr67

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Re: 1996 GS500 Basket Case Build into a GS600R
« Reply #218 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,.....
"Its something you take apart in 2-3 days and takes 10 years to go back together."
-buddha

Offline xunedeinx

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Re: 1996 GS500 Basket Case Build into a GS600R
« Reply #219 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!