2005 GS500F | Scrambler Project

[ShowBizWolf]

That is super awesome... I never thought about putting the drops of hardener into cups first and then just adding the resin on the go. DUH moment for me, that's for sure   

But I totally pre-mark my cups and popsicle sticks sure are great for stirring!!

What kind of mixing cups do you prefer?

[Joester41]

I only thought of measuring the hardener first this past weekend... Not sure why I never thought of it before. 

I've been using short/wide 8oz clear plastic cups for this project. The resin instructions say not to use the wax coated paper cups, however I am pretty sure I've used them in the past on some friends' seat pans with no problem...

What have you fiberglassed in the past?

[ShowBizWolf]

I have never tried wax coated paper cups but I bought some small cups (can't remember the oz size right now) from walmart, fully thinking I'd have to act fast when using them because they were so thin that the resin would eat through. Sure enough if I don't hurry, it eats through the cup haha... oh well !! If I mix up more than 3 to 4 oz at a time, I just double the cup.

I have never fiberglassed for a mold or made an actual object out of it yet. I started using it on my car to fix places on the bumper kit I made... the skirts... also have used it to seal up around patches. I also used it to make a front fender for my gs. OH and I also used it on my van (Idk if you've seen/heard of my Caravan that I turned into a Ninja Turtle van) but I needed a good way to secure the pvc "ray guns" and "satellite dish" to the visor that goes over the windshield.

I absolutely love fiberglass and am super happy with the price of it and how strong it is. What a wonderful and versatile material!!

[Joester41]

Is there a thread somewhere around here with this Ninja Turtle Van? Sounds awesome!

[Big Rich]

Joe / Showbiz: I've used the red Solo cups for measuring & mixing resin. The same cups people play beer pong with - those lines on the sides of the cups are for measuring amounts (the bottom line is 4 ounces IIRC?).

Either way, good work so far Joe.

[ShowBizWolf]

I have heard about those lines on a standard solo cup being measuring lines!! The cups I bought are much smaller than those cups though so I measure with water and mark a bunch of them at a time with sharpie.

I don't have a thread about my van but I did make a facebook page for it... when I put it up on Cardomain back in 2010 when I finished it, I was waking up to a million friend requests each day from strangers  I was like omg no no the van needs its own page LOL

https://www.facebook.com/JohnstownTMNTvan/

Thank you for asking about it Joester, very much appreciated 

[Joester41]

Short update:

Tank is painted, seat is foamed. A little foam shaping and some vinyl on the tank and it will be done...

[Daeouse]

C'est Magnifique!

[AssassinGT]

Gorgeous! Love it

[The fink]

I've really been enjoying this build thread. Keep up the good work! 

[ShowBizWolf]

Tank looks GREAT !!!

[JohnnyC]

Very nice looking bike. Excellent craftsmanship sir!

[Joester41]

Thanks for all the positive feedback!

This week I trimmed down my front fender, installed the turn indicator diodes, adjusted the floats, synced the carbs, and adjusted the idle, it is running solid now. Getting anxious for the first ride, hopefully I get my tank and seat back soon...

BTW, if anybody is interested in any of the parts I designed for my bike, I have copies of the CAD files if you want to make your own.

[Daeouse]

BTW, if anybody is interested in any of the parts I designed for my bike, I have copies of the CAD files if you want to make your own.

YES!!!! That battery tray and Seat mod is killer!!!!!

[Bluesmudge]

Please post those CAD files, your parts are great! What kind of equipment would a shop need to be able to produce these parts? Forgive me, I know nothing about CAD or machining.

Can I ask why the engine guard only covers the front of the engine? Is that a cafe style? Most skid plates I have seen are concerned with protecting the bottom of the engine.

[Joester41]

I will post the .DXF files, they are the format most lasercutting/waterjet cutting shops request for quotes. I have to dig though my emails and see if i can find the files, otherwise i will have to wait till monday (when i have access to my work computer).

The files are basic drawings with the bending and material info, blank shape, plus an isometric view of the formed part for visualization.

Any shop that does laser or water jet cutting of metal should be able to read the files and produce these, it also helps if they have forming/bending capabilities.

The battery box requires welding, so you will need to weld them or find somebody who can. It is designed with tabs, slots and alignment holes, so it goes together pretty intuitively.

[Joester41]

Can I ask why the engine guard only covers the front of the engine? Is that a cafe style? Most skid plates I have seen are concerned with protecting the bottom of the engine.

It is more to protect the front of the engine due to the lack of of the front fender. Also, since it has an under-frame exhaust, I would reduce ground clearance if I extended it further. There is a small bent tab that runs under the front curve of the exhaust, which should help a little.

I am considering doing a 2nd version that runs under and attaches to the other 2 fairing mounting holes, just haven't had the time yet.

[Bluesmudge]

Maybe you could design something like this, but using the fairing mount holes:

[The Buddha]

You have the skills to do it right.
Hats off to ya.

What separates a bike that has been cobbled together in some redneck's garage vs one that is done well IMHO -

Side covers, exposed fasteners, exposed electricals and stuff that does not fit or work right.

Make side covers for it and in fact you should have fabbed around that airbox instead of removing it and K&N filtering it.

And please please please .... DO NOT PAINT IT FLAT BLACK. AKA Murdered out.

Anyway you seen people fit skateboard decks for seat pans ? They look OK, rather, that's not the part of it I dislike the most. Its the rest of the redneck engineering on them.

Cool.
Buddha.

[peteGS]

I don't know how I missed this thread... awesome work!

I have a thing for scramblers and did a more road biased scrambler theme on my 450 including getting a high pipe made up for it.

I have to revisit it late this year/early next year and make a solo seat for it so I can get my Kat registered once it's done, so it's good to see your seat process too as I'll be doing a similar thing real soon.

Great job, love your work... can't wait to see it finished!