1981 GS450E Rebuild

[Guest]

Started into the cutting tonight so I can get it down close enough to work out what I need to do about where it will go over or around the tail light bracket, but between a blunt hacksaw blade (in fact a tool drawer full of them) and sweating like a pig I didn't get as far as I'd have liked to. I really wanted to finish cutting tonight... might have to con the house mate into picking up some new blades tomorrow I think...

[Redneck]

Started into the cutting tonight so I can get it down close enough to work out what I need to do about where it will go over or around the tail light bracket, but between a blunt hacksaw blade (in fact a tool drawer full of them) and sweating like a pig I didn't get as far as I'd have liked to. I really wanted to finish cutting tonight... might have to con the house mate into picking up some new blades tomorrow I think...

Does the word "Jigsaw" mean anything to you. One of the most hand tools to have around for both wood and metal.

Paul

[ged]

Pete thats going to be fun. I cannot imagine how you have worked out the size of the material to fit in there. Thank god mine is plastic, then again maybe not, the hinged flap to my box is already cracked and I had to do some heat welding to get it to swing again. I should have taken a pic.

[Guest]

Does the word "Jigsaw" mean anything to you. One of the most hand tools to have around for both wood and metal.

Paul

Haha yeah it does indeed mean something... far too noisy for 9pm at night unfortunately

There've been a lot of things I've done that would have taken many less hours had I been working on them in the daytime with power tools... alas I'm back to nights again so hand tools only except for drilling as the power drill is thankfully quite quiet...

But thanks for thinking of me again Paul

Pete thats going to be fun. I cannot imagine how you have worked out the size of the material to fit in there. Thank god mine is plastic, then again maybe not, the hinged flap to my box is already cracked and I had to do some heat welding to get it to swing again. I should have taken a pic.

Cheers Greg, fun's one word for it... actually yeah it is the word for it. I've loved doing these bits and pieces along the way, although the tail piece became somewhat of a nightmare with the body filler over the fibre glass...

The measurements are partially guesses as I can get the tape measure in there to do them, but you can't line your eye up properly to work it out. I could take the tail piece off and measure it more accurately, but I'm far too lazy for that...

And yes, you should've taken a pic

[Guest]

My house mate came through with the goods once again, a set of 5 hacksaw blades waiting on the workbench when I got home this avo

So I finished the cutting in no time at all, amazing what a difference a new blade makes...



Then bent all the sides up but left the front mounting brackets flat for the moment:



However, that ain't going in... I thought I'd be able to put it on an angle or pivot it in or something but no way does she fit



So I cut it in half:



Still couldn't quite get it in even like that, but it looks now like I'm going to have to do without the front mounts to be able to get it in without taking the tail piece off.

So I think I'll trim the length of the mounts down rather than cutting them off completely and bend that small bit at the front up so it forms a tray on all sides.

I intend to put some rubber in there for some cushioning so I can use that to hold the two sides together as well as relying on the bolts at the rear. I'll just use the same contact glue I used for the seat foam and it should do the trick nicely there.

[Good Times]

Nice work. Looks great.

[GateKeeper]

Maybe a bigger hammer would have helped you out a bit......

nice work so far

hope you get it in there.....

[7981GS]

It looked so good, why did you cut it?
A little tweeking here and there and it would have been a perfect fit!
Am I missing something in the photo's?

Daniel

[Guest]

Nice work. Looks great.

Well... I reckon it'd look better if I got it to fit

Maybe a bigger hammer would have helped you out a bit......

nice work so far

hope you get it in there.....

Haha yes indeed! I'll get it in there... I swear...

It looked so good, why did you cut it?
A little tweeking here and there and it would have been a perfect fit!
Am I missing something in the photo's?

Daniel

I know Daniel, I didn't want to cut it, but my mind screamed at me to cut it... with the thought if I fold it in half, it would fit. What the photos don't show is that without taking the tail piece, tail light, and rear guard off, there's no way it will go in that opening and be able to be maneuvered into place.

Once I sort the front out and stick the rubber over it, you won't see it's been cut but I'll have a hinge of sorts in the middle I can use to get it through the opening... stay tuned and I hope you'll see success soon

[Guest]

Ok this is getting frustrating... it's so close!

Cut off the end of the front mounts and bent the front up so it's a tray all 'round now:



And this is the rubber I have that I'll be glueing on there as a bit of cushioning:



So I can now get the one side in sort of but my measurements are out as I think I measured too low down, meaning it needs to be shorter:



So I trimmed the front which now lets it sit in almost like it should, but it seems the height of the side is now too tall and it's actually holding it too far forward and too much towards the centre so it doesn't line up with the tail light mounting bolt:



So I've left it there for tonight but I think I know how to finish it off now which means the other half will be much easier, then it's a matter of filing all the jagged edges smooth, glueing the rubber on, and getting it mounted.

Don't think I'll get it done in time for the run on Sunday but hopefully I can at least have it the right shape...

[cowboyup3371]

Looks great Pete. I know it can be aggravating when it's almost there but not quite. Hope you sort it out soon and it does what you want.

I started thinking of a different way to mount my electrics but am hesitant to start it as I'm not sure about where to put it or if the idea would even be smart. I'll probably leave them where they are on the air box for now but I'll follow your ideas here with interest.

[Guest]

Looks great Pete. I know it can be aggravating when it's almost there but not quite. Hope you sort it out soon and it does what you want.

I started thinking of a different way to mount my electrics but am hesitant to start it as I'm not sure about where to put it or if the idea would even be smart. I'll probably leave them where they are on the air box for now but I'll follow your ideas here with interest.

Cheers Scott, I'll be stoked when I get it in there and have somewhere to put my tools and things without need to lug the tank bag everywhere!

Moving the electrics is reasonably straight forward and because I didn't end up moving my battery, the only wiring I had to touch and customise were the runs to the main fuse and starter solenoid and running extras for the single point ground etc.

[Redneck]

Do you ever get the idea that Pete is just dragging this thread out so that he can have the longest running thread in the GSR?

I must just saying is all.

Paul

[spyug]

Do you ever get the idea that Pete is just dragging this thread out so that he can have the longest running thread in the GSR?

I must just saying is all.

Took the words out of my mouth. I haven't followed this thread for awhile and when I looked today I noticed the count and that's exactly went through my mind.....I **** you not. But its ok because he does good work and its very entertaining . Just what we need right now with this crazy weather. Can't ride yet so we need something to keep us "tuned up". Thanks Pete !

Cheers all,
Spyug

[Guest]

Do you ever get the idea that Pete is just dragging this thread out so that he can have the longest running thread in the GSR?

I must just saying is all.

Paul

Took the words out of my mouth. I haven't followed this thread for awhile and when I looked today I noticed the count and that's exactly went through my mind.....I **** you not. But its ok because he does good work and its very entertaining . Just what we need right now with this crazy weather. Can't ride yet so we need something to keep us "tuned up". Thanks Pete !

Cheers all,
Spyug

Hahahahaha now c'mon fellas

Actually the length of the thread hasn't escaped my attention... but you may have noticed I've never said she's actually done yet... there is definitely more I want to do to complete the project... it's just taking longer now coz I get to ride her

And cheers Spyug, it's not all good but some of it turns out ok Glad I keep you amused during your snowy season

As for the tool tray, well I'm probably not getting back to that until Sunday or Monday night at the earliest. Few beers tonight and tomorrow is wash and polish in preparation for the run on Sunday... can't wait for Sunday actually!