The tossed 78 GS1000 rebuild thread.

[IanC]

Where did you get the mounts?

Got them and the swingarm reducer/spacer bushings from Katman.

[steve murdoch]

Where did you get the mounts?

[IanC]

Found a little bit of spare time to get the shock mounts welded on. The same guy will be doing the fabrication of the frame bracing and welding it up but won't have time to do it until June. I was planning on getting it done a bit sooner so I could move on with the project but it is what it is and he's good at what he does so I'll find other things to do for a few weeks.

[IanC]

Been a while since I updated this and progress has been slow with school, work and family leaving me very little free time. The frame was sent off to be sandblasted and inspected prior to laying down a coat of primer. As I somewhat expected there was no indication that the rolled steel frame had gotten hot. So proceeded with this frame for sentimental value and will build a period correct 1978 out of the other frame I have hanging from my garage ceiling.

Frame sandblasted and coated in primer to prevent surface rust while mocking things up.


Donor 1981 GS1100 engine.


Engine loosely in the frame while I figure out mounts.


Fitted 1998 Bandit 1200 rear end and taking measurements to have the shock mounts welded on.


Engine mounts figured out, steering stem bearings/races swapped to accommodate the 2004 GSXR600 front end. ( This front end is for sale, I've decided on an 2005-2006 front end.)


Once the shock mounts are welded on and it's a roller I'll be sending the whole frame to be braced and excess tabs and such cleaned up. I'll have a bit more time to make progress this summer while I'm out of school.

[Nessism]

I'm not so sure about the chassis. All that heat couldn't have been good for the metal. I'm not sure if the chassis is just mild steel or if there are some heat treated sections. Might not be an issue but personally, I'd either talk to someone that knows about that kind of thing or just change the frame to be safe.

[IanC]

Got the rear end off the donor Bandit and that gave me a better idea of what will need to be done to make everything work.

[IanC]

well, check it as I said. It may only be burned paint visible in the photos, but all the chassis bracing in the world won't help you if it bends along those 3 tubes

You going to do the Yoshimura style bracing? The X, the one across the side triangles and under the back top bend are the most important

Once the frame is sandblasted I'll inspect the frame again more thoroughly but I'm not expecting any damage. I'm not decided on the bracing yet. I may just do some gussets.

Did the under-braced swingarm{Davida?] get too damaged in the fire?
Is that why you are swapping to a Bandit arm?

The Metmachex swinger that was on it can probably be salvaged but the orginal intent is to fit a 180 rear tire which is a very tight fit and would require a bit more figuring out. The more simple solution is the Bandit swingarm/brake/wheel combo using Katman's conversion bits.

well, check it as I said. It may only be burned paint visible in the photos, but all the chassis bracing in the world won't help you if it bends along those 3 tubes

You going to do the Yoshimura style bracing? The X, the one across the side triangles and under the back top bend are the most important

Can you post some pictures of that bracing on your super bike replica project?

[steve murdoch]

Did the under-braced swingarm{Davida?] get too damaged in the fire?
Is that why you are swapping to a Bandit arm?

[Big T]

Looking over the frame I don't think there is anything to worry about structurally. If I have any serious concerns I have access to two more titled frames so it's not the end of the world. I'd like to stay with this one purely for sentimental value. I will be adding some bracing to the frame to keep chassis flex to a minimum with the modifications planned and somewhat as a peace of mind.

well, check it as I said. It may only be burned paint visible in the photos, but all the chassis bracing in the world won't help you if it bends along those 3 tubes

You going to do the Yoshimura style bracing? The X, the one across the side triangles and under the back top bend are the most important

[IanC]

Ian

I'd be concerned about the structural integrity of the frame area above the carbs

Since that area is all rusty, wire brush it and see if the frame tubes changed color

While a gas fire might not be too hot, I'd hate to see the frame bend after all of the work you're doing

Looking over the frame I don't think there is anything to worry about structurally. If I have any serious concerns I have access to two more titled frames so it's not the end of the world. I'd like to stay with this one purely for sentimental value. I will be adding some bracing to the frame to keep chassis flex to a minimum with the modifications planned and somewhat as a peace of mind.

[Big T]

Ian

I'd be concerned about the structural integrity of the frame area above the carbs

Since that area is all rusty, wire brush it and see if the frame tubes changed color

While a gas fire might not be too hot, I'd hate to see the frame bend after all of the work you're doing

[IanC]

The spark inside the switch as the contacts broke lit it up probably.

That was my assumption too.

[chuck hahn]

The spark inside the switch as the contacts broke lit it up probably.

[IanC]

Yikes!
Care to share what the "series of unfortunate events" were.
Glad there were no injuries and will certainly follow this re-re-rebuild.

Geeze!
Those pictures define crash and burn. Well at least the burn part...
What happened?

A trusted and very experienced rider borrowed the GS, as his GS is down for maintenance, to meet some friends for a lunch ride. It was a cold and rainy day causing some fogging on his shield. Last he really remembers is trying to clear some fog from his visor. What we've been able to piece together is that he was clearing his visor and didn't notice the truck and rider performing an emergency stop in front of him. He saw it too late and tried to avoid hitting the other rider but knicked the right saddlebag ricocheting the GS to the right. He must have hit a curb or something of that nature because there was no slide damage on his gear but significant impact damage to his helmet and left side of his body. He suffered several broken bones and some internal bleeding. As far as I can tell from the wreckage the actual accident damage to the GS was fairly light. As the rider was being loaded up in the ambulance his riding buddy noticed the light was on, as soon as he turned the ignition switch to turn it off the bike went up in flames. Three weeks later, the rider is healing up fairly well but still has a ways to go yet, his riding buddy was fine and has settled with the insurance company and my GS is on it's way to yet another evolutionary leap.

Which Bandit swinger 600 or 1200? Can you send me some pic's/drawings of the pieces that you are making to mount the shocks on it as I am doing the same thing with the 1200 swinger currently myself. TIA!

I'll be using a 1200 Bandit swinger. I found this site that sells everything you need to make the swap work. It was a huge load off the modification workload to find: http://www.parts.suzuki-katana.com/. It's my understanding that the owner is a member here so bonus for supporting a member.