GS1100- "Project NimRod"- Shafty

It is coming together nicely. El G.

Thanks for the comments and concern. The pvc spacers are working well during my tests. The clip ons don't move at all...I didn't have them tightened enough when I first installed them and they moved when I forced them. After further tightening they are rock solid. As far as I've seen they wont go anywhere. Also I had plenty on threads to tighten and still have a few more.

[hjfisk]

Not getting much done today..it's raining and I'm doing this build out of doors. I solved the cbr clip on size issue though. Went to Lowes and got some pvc pipe that I'm using as internal spacers. I don't see why they wouldn't hold up and they give the clip ons the approximent 1 3/8 inside diameter to match the fork tubes...before bolts are tightened down all the way. I split the pipe into two halves and cut them to the clip on width. Picture shows both halves taped inside to get final measurements. Also got a 1x8 poplar board to use as a seat pan mock up. It is the perfect 7 1/4 width to match frame. Spent $5 on the pvc and board and $17 dollars on Ebay for the clip ons.

I don't think I would trust that PVC as a spacer for clip ons, why don't you just get some Vortex clip-ons that are made for your 37mm fork tubes and be safe. They are readily available through Parts unlimited. Just saying safer is better

this pic was for the post below.

Another view. I have a new tail light to use as a brake light once i figure out how this tail will work. I have removed the center stand to if I hadn't already mentioned it.

The tail will either be removable or slid back to reveal more seat for a passenger. I haven't decided how to proceed.

As for the tank...I still plan to use the honda tank on this bike. Di-electric rust removal was a bust...I must be doing something wrong. Ill use gravel and sand if all else fails and maybe reline the tank.

Only question is if I can adapt the suzuki petcock to the honda tank. Honda tank has good petcock but it doesn't have a vacuum line. I need to research this issue further.

Bike as it looks today. Tomorrow I will get the seat and tail roughed in.

I still need to rewire and mount the power on/off, start and hi beam buttons and toggles. I also need to find a mounting location for the choke lever.

By passed the clutch safety and removed the side stand indicator button. I'm not running any guages so I don't need the side stand light. I've tested my Sprint Evo mobile phone with several GPS MPH and Tach apps. Also have Maps, and other info one one easy to use main screen. I will be looking for ways to attach it to the handle bar clamps and wiring a charger into the fuse panel.

Layed the bump stop on to get an idea what I'm working with.

I also removed the chrome side panels from the air box covers. I will be reworking the origional front fender and adding it to the look.

I also cut off the rear of the frame just in front of the stock seat support.

Also sold the side covers and removed the side cover mounting tabs from the frame.

Finally have the whole front end together. Installed the headlight, throttle housing and grips.

As I said I ended up with Approximately 1 inch of fork tubes above the trees. Everything has turned out as I have planned. I love the look of the clip ons.

No problem chopping up the Kawasaki tank..just follow the dotted line.

More pics tomorrow...rain today.

Inside the tank

Have everything together to do a di-electric rust removal in the honda tank. Using the battery charger, in the open air over a couple days. I have to wait for the rain to subside. Rust is only surface.

New grips ($17) with new dirt bike throttle assembly ($13).

Donor for my bump stop.

Made some purchases today. Looked through a salvage yard at local Yamaha dealer. Found an old 81 Honda cb 900 tank (with good petcock)...perfect for what I want to do after pounding knee dents in the sides. Also found a small Kawasaki kh 400 tank that is perfect for building my bump stop. I'm going to chop this thing up like guys did long ago. It measures between 7 and 8 inches wide which is the approximate width of the frame tail. I'm excited because I got em both for $25.

Also got a CR Competition dirt bike throttle housing to replace stock housing. I like the cleaner look this will add. I'll be wiring headlight control-starter button-on/off switch to toggle switches somewhere under the tank.

Ordered new clutch cable from an ES..It's alittle shorter than the L.