1993 re-hashed

[Sporty]

Here is the first attempt at making a rear frame cover panel from .040" thick aluminum sheet metal.

The little tabs that go into the side covers complicated it.  They aren't supposed to be even with the edge as I made it. They are inset a little bit. An additional tight bend, folding the tab flat against the panel, then back to fit the slot might be better.





What are the fasteners like? Sheet metal screws?  Metric machine screws do not fit the clip nuts.



The fit isn't too bad. With a more practice, a better result is likely.  I'll paint it and see if this one looks passable.

[ShowBizWolf]

I've replaced many of the fasteners on my bike with stainless bits so I'm not sure what was originally there... but that center panel on my bike is held in place by two round head allen bolts and nylon lock nuts.

Bike is looking great btw Sporty 

[Sporty]

I've replaced many of the fasteners on my bike with stainless bits so I'm not sure what was originally there... but that center panel on my bike is held in place by two round head allen bolts and nylon lock nuts.

Bike is looking great btw Sporty 

Thanks ShowBiz!

[Sporty]

Looking at the drawing again, it sort of looks that #14 might be a sheet metal screw..

The #16 clip nuts aren't accepting machine screws.






I had to look up if there are metric sheet metal screws. (and of course there are) I may have some of these around (from cars)



The #15 washers as they list it, might actually be rubber from this sample photo.

[Sporty]

Prepped and Painted the cover last night....  today it's looking good enough to use... I'll live with a little gap at the sides in the rear.

[ShowBizWolf]

That looks very nice!! I agree about those #15's.

[Sporty]

I saw that the rear panel usually has a Suzuki decal. Suzuki doesn't offer it, and I didn't find it on eBay or etsy ... close, but either not the correct color or the correct size.

This "good enough"  decal was made with a P-Touch label maker.
It's not the same font Suzuki uses, but the closest the label maker has.

Wet sanded the black, applied the Suzuki decal, then sprayed three coats of clear in the Aldi cardboard spray booth
(no laquer was applied, just using the can to hold the panel)

[Sporty]

Trying to wrap it up before winterizing.

Found two used metric sheet metal screws. Probably from a GM car.  Made some crude rubber washers and cut the screws down a bit.

The end result isn't too bad. At least the bike looks complete and I have some closure on the project.

[Sporty]

Delivery today!

Found a set of Racetech Springs in .80 kg at a good price!

I still have to winterize the bike and will swap the springs and then get it ready for storage.

[Sporty]

I went down to the barn to winterize the motorcycles.

After taking off the seat to remove the battery, it's apparent that the mice work fast. They're already filling up the tool kit compartment!



I had drained the float bowls after I ran it last, but it seems the petcock is letting some gas through. Not only that, there was some water in the bowls     I've no idea how there could be water... unless it's the ethanol in the gasoline. So I removed the tank and drained it, then drained all the fuel lines. Sprayed some WD40 into the bowls and let it drain back out. Next is rust prevention oil and a bag!

BTW,  I found out the identity of foreign object that was in the fuel tank when we bought the bike. Its this fuel stabilizer filter. I was over at my riding buddies shop and he had a ten pack of the things. They hang into the fuel tank on a very thin string. I have a couple and might try them in other fuel tanks.  (The GS500E tank is drained and rust preventer put in)