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Yeah, I've been looking at that. I may have to notch the hoop rails and pull it up at the tail. Thought I'd have clearance until the new tire was on. I was debating doing it before painting the frame, but since the prep was done I went ahead and painted since things rust before your eyes in Louisiana. should be a straightforward fix and just a small touch up on the paint after welding.
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I've bene able to get some more work done, but haven't updated on here, so here's a bit of a catch up:
Taking the sound advice of hillsy, i scrapped the rear hoop and went back to the drawing board. I was going to notch the hoop, give it an upsweep and weld, but I wasn't happy with how it was turning out. Cut the hoop off entirely and went with a factory upswept hoop. Ended up with a slightly longer frame than I was originally intending, but I'm happy with it. It does preserve the option of riding 2-up if I throw the passenger pegs back on in the future.
I got my seat frame fabricated. The top plat rivets are holding the rails together at the moment, but I'll finish up with welds when I get weld up the frame hoop. I wanted to raise the seat level for a few reasons, first being my height and wanting a little more leg room, but also to match the tank height a little better and also give a little more room for the electronics tray under the seat. Speaking of which, I wasn't happy with how the tray was sitting or its capacity, so I went back to the drawing board with that as well. It now hangs below the frame by a little under an inch, but by doing so I created enough room for the battery and all (minus the r/r) to sit hidden under the seat. I need to source the foam and material for the cover, but I've predrilled holes to attach the cover to the seat pan with pop rivets so the seat cover itself is way down on my list of things to do. Not pictured below are the tank mounts. I'll be welding in a couple tabs, and I have elevator bolts punched through the seat pan to use to attach to the bike.
I'm hoping to get to the welding this weekend. It's been a long time since I've welded, so my free time might just be practice on scrap until I get back in the groove and start on the frame itself.
Found out recently that I'll be moving this summer across country, so I'm trying to ramp up my work pace to get this done before I head out. I'd really rather not move with components in boxes and have to worry about losing something.
Taking the sound advice of hillsy, i scrapped the rear hoop and went back to the drawing board. I was going to notch the hoop, give it an upsweep and weld, but I wasn't happy with how it was turning out. Cut the hoop off entirely and went with a factory upswept hoop. Ended up with a slightly longer frame than I was originally intending, but I'm happy with it. It does preserve the option of riding 2-up if I throw the passenger pegs back on in the future.
I got my seat frame fabricated. The top plat rivets are holding the rails together at the moment, but I'll finish up with welds when I get weld up the frame hoop. I wanted to raise the seat level for a few reasons, first being my height and wanting a little more leg room, but also to match the tank height a little better and also give a little more room for the electronics tray under the seat. Speaking of which, I wasn't happy with how the tray was sitting or its capacity, so I went back to the drawing board with that as well. It now hangs below the frame by a little under an inch, but by doing so I created enough room for the battery and all (minus the r/r) to sit hidden under the seat. I need to source the foam and material for the cover, but I've predrilled holes to attach the cover to the seat pan with pop rivets so the seat cover itself is way down on my list of things to do. Not pictured below are the tank mounts. I'll be welding in a couple tabs, and I have elevator bolts punched through the seat pan to use to attach to the bike.
I'm hoping to get to the welding this weekend. It's been a long time since I've welded, so my free time might just be practice on scrap until I get back in the groove and start on the frame itself.
Found out recently that I'll be moving this summer across country, so I'm trying to ramp up my work pace to get this done before I head out. I'd really rather not move with components in boxes and have to worry about losing something.
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PO had lots of little interesting alterations, but that one I didn't catch. Good eye!
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I got to the welding, or rather, had some help with the welding. Nice thing about most Army bases is they have a pretty well equipped auto shop. I had been told you could use the welding equipment so I brought a bunch of scrap to brush up before tackling the frame. Turned out that they have a guy there and he does the welding for you. Didn't hurt my feelings especially since you pay by the hour, so for $16, I got the rear hoop sorted out, two mounting bars for the seat pan, and the electrical tray welded in place. They weren't the prettiest welds, but a grinder and paint made him the welder he ain't.
Also got the engine cleaned, taped, and painted. Doesn't look too bad. I shot VHT satin, and it's a bit glossier than I thought it would be, but I'm happy with it. I still need to polish up the covers, but my focus right now is on getting her back together and I can pull the covers off down the road to pretty them up a bit.
I have to take the frame in to get the VIN inspected by a law enforcement officer since the PO had a CA title and I'm registering in FL but have to do it by mail. Now's the time to, since my hatchback won't quite fit an assembled GS. Once I get that done in the next day or two, I'm going to try the lowering the frame over the engine method to try and avoid scratching up either the frame or the engine. I might use the heat gun to try and cure the side of the engine that will be up against the padding on the garage floor to minimize damage there.
I got my wiring ordered, and once the engine is in and I reassemble the front and rear, that's probably my next step. I'm rewiring from scratch with the help of a Marty unit from NWT Cycletronics, so that should be an adventure.
Also got the engine cleaned, taped, and painted. Doesn't look too bad. I shot VHT satin, and it's a bit glossier than I thought it would be, but I'm happy with it. I still need to polish up the covers, but my focus right now is on getting her back together and I can pull the covers off down the road to pretty them up a bit.
I have to take the frame in to get the VIN inspected by a law enforcement officer since the PO had a CA title and I'm registering in FL but have to do it by mail. Now's the time to, since my hatchback won't quite fit an assembled GS. Once I get that done in the next day or two, I'm going to try the lowering the frame over the engine method to try and avoid scratching up either the frame or the engine. I might use the heat gun to try and cure the side of the engine that will be up against the padding on the garage floor to minimize damage there.
I got my wiring ordered, and once the engine is in and I reassemble the front and rear, that's probably my next step. I'm rewiring from scratch with the help of a Marty unit from NWT Cycletronics, so that should be an adventure.
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Update: I am an idiot. I took the cam chain tensioner off to paint the engine. Figured I’d go ahead and check the valve clearances while the engine is out and it would be easier. Rotated the engine a bunch of times without the tensioner in and jumped some teeth on the exhaust. Good times.
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Always learning something!
Got the issue sorted out. When I noticed the issue, the exhaust cam was a full 90 degrees off and counting the links I was at 19 not 20 as per the manual. Oh well, gave me a chance to check out the journals for wear. They spec'd out okay, and the valve tappets are all in tolerance, so on to the next! Hopefully the next update has me posting a roller with a mounted engine.
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The engine is in! It feels like a big step forward in terms of getting this project towards the finish line. Since I had the frame stripped down for welding and paint, I used the engine on its side method and lowered the frame over it. Still a PITA for one person, but it's in with only one small scratch on the engine paint courtesy of the rear engine mount tab. Should be an easy touch up there.
With that done and the front/rear reassembled, I moved back to the carbs. I adjusted the float height and got the bench sync done. The carb holder boots are in good shape and still pliant, so I threw on the new O-rings and put those on the engine. The carbs apparently got very comfortable in their bubble wrap cocoon and did not want to go back on the bike, so I threw a short 2x4 behind the carbs, and a ratchet strap around the front of the frame helped them slide right in.
With that buttoned up, I pulled the exhaust down from the rafters. I had intended on keeping the stock exhaust until the project fund built back up, but apparently I didn't pay much attention to it when I pulled it off. There's a lovely rust hole in the bottom of one and the other would make an excellent rattle for a baby gorilla with all the bits and bobs loose inside. The headers are in good shape so I'm probably going to cut the mufflers off and use some inexpensive aftermarkets for the time being until I eventually switch to a 4-1. I went ahead and mounted them so I could get my rearset brackets mocked up.
Next up: Waiting on wiring connectors to arrive, so in the meantime I'll be getting the rear mudguard finished out. I'm trying to use the original guard, just cut down a bit to fit the project. The original part is pretty rough around the edges so I don't feel too bad about chopping it. After that, I need to make some brackets for the SH775 since the original electronics mounting bracket has been deleted. After that, hopefully onto the wiring!
Here's where it started:
And here's where it's at:
With that done and the front/rear reassembled, I moved back to the carbs. I adjusted the float height and got the bench sync done. The carb holder boots are in good shape and still pliant, so I threw on the new O-rings and put those on the engine. The carbs apparently got very comfortable in their bubble wrap cocoon and did not want to go back on the bike, so I threw a short 2x4 behind the carbs, and a ratchet strap around the front of the frame helped them slide right in.
With that buttoned up, I pulled the exhaust down from the rafters. I had intended on keeping the stock exhaust until the project fund built back up, but apparently I didn't pay much attention to it when I pulled it off. There's a lovely rust hole in the bottom of one and the other would make an excellent rattle for a baby gorilla with all the bits and bobs loose inside. The headers are in good shape so I'm probably going to cut the mufflers off and use some inexpensive aftermarkets for the time being until I eventually switch to a 4-1. I went ahead and mounted them so I could get my rearset brackets mocked up.
Next up: Waiting on wiring connectors to arrive, so in the meantime I'll be getting the rear mudguard finished out. I'm trying to use the original guard, just cut down a bit to fit the project. The original part is pretty rough around the edges so I don't feel too bad about chopping it. After that, I need to make some brackets for the SH775 since the original electronics mounting bracket has been deleted. After that, hopefully onto the wiring!
Here's where it started:
And here's where it's at:
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No pictures today, but lots of work has gotten done.
I bit the bullet and ordered a Delkevic 4-1. It's designed for a GS1000E, but the install was pretty quick and painless. The only modification, as others have done, was drilling a new hold in the muffler mounting bracket. It's on and I'm very happy with the look of it. Crazy how much lighter it is than the stock exhaust.
I settled on relocating the R/R to the front behind the headlight bucket. Lots of airflow which will hopefully keep the charging system happy. Had to make a bracket for it, but that didn't take too long yesterday. Just waiting for the paint to dry on the bracket then it'll be mounted up.
I have the front end wired up with the help of a kit from Vintage Connections. Side note on that, I've always hated doing wiring, but with a quality ratcheting crimper, it was actually an enjoyable process. The money on the tool was worth every penny just for making me not hate the process let alone ensuring that the connections are up to standard. Only thing left to wire on the front end is tying in the Triumph pigtail for the SH775 into the new harness.
I have all wiring run and gathered with cable ties until the loom gets delivered. For the electrical, I need to add some connectors on the back end in the electrical tray and then link it up to the NWT box that I plan on using.
Up next is finishing up the wiring harness and getting the electrical all buttoned up. That includes figuring out the mounting for some non-L coils since the ones off the bike were shot.
Most of the big ticket items are already purchased, the biggest expense left will be the brake lines, but I'm holding off on ordering those until I get the rearsets done so I can do a final measurement on what i need in the rear and make sure the clocking is right.
Getting closer! Once the electrical is done, just need to get the carbs put back in so I can do the first test fire!
I bit the bullet and ordered a Delkevic 4-1. It's designed for a GS1000E, but the install was pretty quick and painless. The only modification, as others have done, was drilling a new hold in the muffler mounting bracket. It's on and I'm very happy with the look of it. Crazy how much lighter it is than the stock exhaust.
I settled on relocating the R/R to the front behind the headlight bucket. Lots of airflow which will hopefully keep the charging system happy. Had to make a bracket for it, but that didn't take too long yesterday. Just waiting for the paint to dry on the bracket then it'll be mounted up.
I have the front end wired up with the help of a kit from Vintage Connections. Side note on that, I've always hated doing wiring, but with a quality ratcheting crimper, it was actually an enjoyable process. The money on the tool was worth every penny just for making me not hate the process let alone ensuring that the connections are up to standard. Only thing left to wire on the front end is tying in the Triumph pigtail for the SH775 into the new harness.
I have all wiring run and gathered with cable ties until the loom gets delivered. For the electrical, I need to add some connectors on the back end in the electrical tray and then link it up to the NWT box that I plan on using.
Up next is finishing up the wiring harness and getting the electrical all buttoned up. That includes figuring out the mounting for some non-L coils since the ones off the bike were shot.
Most of the big ticket items are already purchased, the biggest expense left will be the brake lines, but I'm holding off on ordering those until I get the rearsets done so I can do a final measurement on what i need in the rear and make sure the clocking is right.
Getting closer! Once the electrical is done, just need to get the carbs put back in so I can do the first test fire!
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I'm not dead, and neither is the project! I moved across country last summer, so between packing, unpacking and getting my shop set up again, the bike took a backseat for a while.
Though In haven't been updating, I have gotten a fair amount done:
- Electrical install complete.
- Rebuilt front forks with Sonic Springs
- Hayabusa rearsets installed with mounts that I fabricated
- Reworked the old rear fender to fit under chopped frame
- Added a mudguard to keep air filters happy
- Streamlined the triple tree clamp by getting rid of the old handlebar mounts
- Made new clutch/throttle/choke cables
- Mounted up new 4-1 exhaust
- Too many bits and bobs to remember
Left on the to do list:
- Install SS brake lines (arriving later this week)
- Sew up a seat cover and get that put on
- tune the carbs
- Figure out a catch can of some sort
- Paint tank/fender (I shot some white that I had laying around for rust prevention, and I'll probably hold off on the actual paint job until next winter so I can enjoy the season)
- Finally ride the damn thing
I'm getting close!
Though In haven't been updating, I have gotten a fair amount done:
- Electrical install complete.
- Rebuilt front forks with Sonic Springs
- Hayabusa rearsets installed with mounts that I fabricated
- Reworked the old rear fender to fit under chopped frame
- Added a mudguard to keep air filters happy
- Streamlined the triple tree clamp by getting rid of the old handlebar mounts
- Made new clutch/throttle/choke cables
- Mounted up new 4-1 exhaust
- Too many bits and bobs to remember
Left on the to do list:
- Install SS brake lines (arriving later this week)
- Sew up a seat cover and get that put on
- tune the carbs
- Figure out a catch can of some sort
- Paint tank/fender (I shot some white that I had laying around for rust prevention, and I'll probably hold off on the actual paint job until next winter so I can enjoy the season)
- Finally ride the damn thing
I'm getting close!
My azz hurts just looking at it. Teasing, I know you're still working on the seat. Looks good. Hopefully you've got the jetting worked out for CVs with the pods and 4-1.
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Your eyes are telling the truth! She’s not what I’d contemplate calling comfortable just yet! I have 3 inches of high density foam from a cushy exercise mat material on there now. It was close enough to help me get my rear sets in the right place. Don’t worry though, definitely more padding coming!
When I rebuilt the carbs I rejected with a dynojet kit, so I should be in the neighborhood, though some time with a still to be purchased carbtune will tell the tale.
I have a shorty front fender around that might look pretty sweet on that thing.... 
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I have a shorty front fender around that might look pretty sweet on that thing....
That’s on my to do list, actually, and I have a spare fender that I’ve chopped down that I might end up using. But if you’re looking to get rid of yours, shoot me a picture and what you’re asking for it. Probably would look better than what I’m trying to fabricate!
And another.....
