GS450 Mega Build

I don't have a lathe, so I am going to have to farm these out, meaning it will be awhile before I can finally bolt these up.

Talk to Phinney Bay Machine Works in Bremerton..

http://www.pbmwgroup.com/

The owner used to race GS's and makes quite a few custom parts for em..
He's ok with making a few one off bike parts.


Nice work.. Does the speedo drive still fit with the spacers?

Yeah

that's what I thought. I just need the lenses and trim rings, as the body will need to be mounted differently. I found one source for them pretty cheaply:

3" lights

looks like standart spot lights .

you can find those at any hardware store .

* although they look good , the ilumination is poor . try to find halogen lights.

Moving along....

Still working on the front brakes sadly. I've spent about 15+ hours in the shop this week fiddling around with them. I am on prototype number 3 and have hit a few sticky wickets. The first two versions didn't provide enough strength. With all of the offset problems with the rotor, I had only .125" of space on the inside to fit up a bracket. I tried beefing up a that version but it felt flimsy. I came up with another version that sits outside the stock GSXR forks, and then via spacers, goes back to the calipers.

I don't have a lathe, so I am going to have to farm these out, meaning it will be awhile before I can finally bolt these up.



And then a little inspiration for the front end. Anyone got a source for these lights??

Nope

it's a stock 19" wheel from an '80 L model. Love the avatar!

[pete]

Looking good Scotty... that will stop so much better than a stock 450

amazing job .

is this stock 16 wheel?

Spacers started

Well, it turns out .25" (6.3mm) is just right for spacing out the rotors. I cut them out of Aluminum with a template, circle cutter, holesaw, jigsaw, and file. Whew! The rotors clear by a few mm's.

Major Setback? You be the judge....

Finally got in the shop today. Cut and filed the spacers for between the bearings and for centering. Things looked really good until I through the front wheel on to see if things would line up ok. Then I noticed, that yes indeed, the GSXR calipers are VERY wide compared to stockers and hit the mag. That means if I want to run the stock wheels, I can't use these calipers. Or, I have to run them upside down, or reversed. Think I could space the rotors with washers?





Perhaps like this?

[Charlie G]

Thanks for the ideas. I want to hang onto my Mac unit and try to alter to a more pleasurable tone.

cg

Pipes

I'm not sure what route I am going to take with the pipes yet. These stock ones are crap for sure. You looking to part ways with your Mac? I have a spare set of headers, and was thinking about making my own pipes and baffles. Check out this link for more ideas:

http://dotheton.com/index.php?topic=11248.0

Once I figured out the right template it made using and printing these things up so much easier. The main default templates are crap for exact measurement. I use architectural millimeters and have been impressed so far. Not too bad for a free program!

i love it, i, um...aquired a copy of the pro version, used it to design a couple turbo manifolds. Never went through with making them, just needed somethintg to kill some time in class.

[Charlie G]

Scotty,

What kind of exhaust are you going to wind up with in the end? Mac is the only after market header pipe I know of, not that I know it all. I really dislike it's sound. Tinney is the way I discribe it. I've thought of doing some reasearch on altering the internals with additional baffels, to deepen the tone. I have the stock set, which the PO gave me.

cg

Yup

Once I figured out the right template it made using and printing these things up so much easier. The main default templates are crap for exact measurement. I use architectural millimeters and have been impressed so far. Not too bad for a free program!

This build looks amazing. Did you draw up the majority of the sketches in Google's program?