1983 GS 650G Full Size Café Project

[Mop Bucket]

Yippie

Good bye dent! I wrapped a cloth around one of my wrenches and stuck it in the fuel gauge hole. I was able to pry out the dent!

Yippie!

[Mop Bucket]

I was lucky enough to find original muffler covers at Babbits. The only problem with them is the mounting hardware is also discontinued. I fabed up some brackets. I have no idea what the original look like. Does anyone have a picture of the front mounting bracket/whatever?

Brand new, well 30 years old but in original packaging and one was open with 30 years of dust on it.



Started with my typical fabrication material





The bracket





They worked pretty good but having the original or something similar would be nice.



Final results, shiny new 30 year old muffler covers

[psyguy]

Good effort on that tank dent! It would have been a shame to live with a dented tank after all the fine work you've done... Watching with interest...

[Mop Bucket]

Thanks psyguy

I finished the setup of the rear fender and hook up the light. Love the light but I am not sure it is bright enough. I know most Cafe builds go for minimal attachments and on this build I am going for functional yet 1960's racer style. I will add more reflectors as if I had purchased the bike new. I am also thinking of extra lighting. One idea is to have the whole tail section glow red when the brakes are applied. The tail is hollow and open to the air. Having a bunch of LED's up in there might be what is needed. The side of the fender as a great place to mount some lights also. Would be great visibility yet not distract from the look. Maybe some flush mount lights or something. More on that later

Here is the back view of the light, plates, reflector and fender.



The ridge where the fender is mounted to the frame is one location I was thinking of adding the flush lighting. If I can find small enough DOT lights I might do running lights, brake and turn signals.

[AF_Bill]

Nice paint job! I'm diggin the white (my 650 is lol). Can't wait to see it all together.

[Mop Bucket]

Nice paint job! I'm diggin the white (my 650 is lol). Can't wait to see it all together.

Thanks, have any pictures? Sounds like an interesting build, single seated and all.

I purchased a few more things for the build, retro turn signals, White retro grips and some accent lights. I went shopping instead of sanding. Since i am supposed to wait 7 days after painting. I cant wait to finish. Still have some electrical and seat to do. Oh, I keep looking at my not so sparkly other parts and the urge to tear down the bike and paint is growing. Don't know if I have the will power to stop.

[AF_Bill]

My pics are in this section. Check out "Broken Promise" and it shows a few pics of my progress. I haven't done anything lately because of deployments and my other project/currently running bike.

[spyug]

Nice job. Well conceived and executed and I too am looking forward to seeing the finished product.

On that note, I also think you need to tear her down and clean, polish and paint the engine, forks, wheels and frame. It would be a shame to hang all the nice new 'tins" on the dingy frame.

When I do a build, I start with the frame and engine and work "outward". The bodywork is the last to get done. Admittedly its a lot more work but the end result looks a lot more complete to me.

Good luck with the rest of the build whatever you decide to do.

Cheers,
spyug

[Mop Bucket]

On that note, I also think you need to tear her down and clean, polish and paint the engine, forks, wheels and frame. It would be a shame to hang all the nice new 'tins" on the dingy frame.

When I do a build, I start with the frame and engine and work "outward". The bodywork is the last to get done. Admittedly its a lot more work but the end result looks a lot more complete to me.

Good luck with the rest of the build whatever you decide to do.

Cheers,
spyug

You know wrenching is addictive?! Thanks, you just added a couple more months to the build. I totally agree that it needs to be stripped down and every time I look at the speedo and battery box and a few other places my hands shake. I was going to wait until this or next winter or when I retire to paint and polish. Just like I was going to wait until winter to paint. Now...

[Mop Bucket]

Finished the paint! They are ok for my first attempt. I learned a lot and I think next time it will go a lot faster and look a bit better. I had to post on paint since I sanded and started buffing and it looked like crap. Here is the thread Here. Now it is decent and semi glossy. Almost done with the tins and seat. Still trying to find marine grade leather for the tail and maybe foam.












Still have to finish the following seat, eletrical, complete tear down and paint and polish parts

[psyguy]

Thats looking VERY good!

May I suggest though a shortened rear mudgard would give it a more sporty look... imho...

[Mop Bucket]

Thats looking VERY good!

May I suggest though a shortened rear mudgard would give it a more sporty look... imho...

You may I have pulled the fender and does look better. I am hoping to use the bike for a daily commuter and the fender will go along way in keeping me dry, not that it rains much in the desert. Plus it will keep the bike legal in 49 states. Don't think in Califorina any bike is legal now days.

I am taking a break for awhile. The bike isn't running right after putting it back together so time to regroup and do other things.

[pete]

Mate it looks great! I had my concerns that the tail piece would be too big, but now it's painted and together it flows real well.

The only thing is what psyguy already said and what you're looking at which is that rear guard...

[Erki]

Looks awesome. great work.

[psyguy]

the fender will go along way in keeping me dry

i would think that given the width of the rear cowl and the reg plate, that piece of plastic mudguard wouldnt improve the rain protection that much?

as for being legal, if you were to cut it right under the bottom of the reg plate would that work? it does over here where i live