1996 GS500 Basket Case Build into a GS600R

Started by cbrfxr67, April 12, 2011, 02:54:10 PM

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cbrfxr67

#20
April 21, 2011, 07:17:54 AM
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.
"Its something you take apart in 2-3 days and takes 10 years to go back together."
-buddha

tb0lt

#21
April 21, 2011, 08:03:04 AM
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.

cbrfxr67

#22
April 23, 2011, 07:45:37 PM Last Edit: January 17, 2020, 10:28:14 AM by cbrfxr67
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.

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

cbrfxr67

#23
April 24, 2011, 06:45:36 PM Last Edit: January 17, 2020, 10:29:08 AM by cbrfxr67
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. 
"Its something you take apart in 2-3 days and takes 10 years to go back together."
-buddha

KlaXon

#24
April 25, 2011, 02:10:23 AM
Dude this will be awesome bike  :bowdown:
Good luck to you. Keep going.

Chancegs1996

#25
April 26, 2011, 02:06:08 PM
Hey dad its me this is going to be a really good bike... Thx for doing it!!!  :2guns: :woohoo: :thumb:

Fry

#26
April 26, 2011, 06:52:30 PM
Awesome Build....Love your motivation...Following this thread closely, Great Work.
Have you learned the lessons only of those who admired you, and were tender with you, and stood aside for you? Have you not learned great lessons from those who braced themselves against you, and disputed passage with you?
Walt Whitman

cbrfxr67

#27
April 27, 2011, 09:22:06 AM Last Edit: January 17, 2020, 10:32:56 AM by cbrfxr67

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

cbrfxr67

#28
April 27, 2011, 07:35:48 PM Last Edit: January 17, 2020, 10:30:41 AM by cbrfxr67

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

tb0lt

#29
April 27, 2011, 08:17:26 PM
This is moving pretty fast. Exciting stuff.  :woohoo:

jeffdodge

#30
April 28, 2011, 07:36:00 AM
Keep up the good work!  :thumb:

cbrfxr67

#31
April 29, 2011, 07:03:45 AM Last Edit: January 17, 2020, 10:33:21 AM by cbrfxr67
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.
"Its something you take apart in 2-3 days and takes 10 years to go back together."
-buddha

Shepa

#32
April 29, 2011, 11:27:24 PM
Nice project!


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.
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.

cbrfxr67

#33
April 30, 2011, 03:12:42 PM Last Edit: January 17, 2020, 10:38:54 AM by cbrfxr67
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.  Primed out frame work.  You can see I left the old brackets, except for on the removable piece.  I know, I know, I just can't stop cutting, grinding and welding.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.
"Its something you take apart in 2-3 days and takes 10 years to go back together."
-buddha

5thAve

#34
April 30, 2011, 05:27:57 PM
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.
GS500EM currently undergoing major open-heart surgery.
Coming eventually: 541cc with 78mm Wiseco pistons; K&N Lunchbox; Vance & Hines; 40 pilot / 147.5 main jets; Progressive fork springs; 15W fork oil; Katana 750 shock

VFR750FM beautifully stock.
XV750 Virago 1981 - sold
XL185s 1984 - sold

jeffdodge

#35
April 30, 2011, 05:37:07 PM
I also agree with that. Lines work better in pic 1.

Big Rich

#36
April 30, 2011, 05:41:10 PM
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!
83 GR650 (riding / rolling project)

It's opener there in the wide open air...

cbrfxr67

#37
May 01, 2011, 06:56:50 AM
I might have to change the title,...to quote tb0lt, it's a GS 600 now.   :icon_mrgreen:
"Its something you take apart in 2-3 days and takes 10 years to go back together."
-buddha

cbrfxr67

#38
May 01, 2011, 08:34:51 PM Last Edit: January 17, 2020, 10:40:34 AM by cbrfxr67
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.

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

jeffdodge

#39
May 02, 2011, 09:30:37 AM
 :cheers:

watching...
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