1981 GS450E Rebuild

[Redneck]

Only other thing I could think of was did you use a thin gasket material between the lexan and the brackets. Lots of vibration in that area, gaskets would help keep her snug and in place.

Paul

 

[Guest]

Hey pete,

Great looking little windscreen project. Why not paint the brackets so they 'blend' a bit better with the black headlight and ears, and back of the gauges. If your dead opposed to this idea, then I would go for a brushed finish. Don't need anything shiny there.

It is looking awesome, kudos for the originality to make your own.

Cheers!

Cheers Tim! I thought about the black... but the thought just doesn't gel this time, not sure why. I think partly it's the fact that if the brackets are wrong, it's easy enough to make more, so painting could be a wasted effort.

I reckon brushed is right though, definitly agree with you there

I still also have every intention of running an Acewell gauge up the front to sort out the dodgy bouncy speedo/tacho needles once and for all (at least they're useable for the moment), and that will get rid of the big black box, and I will likely make a bracket for that out of some 2.5mm alu. as well, so hopefully it should all work together...

Only other thing I could think of was did you use a thin gasket material between the lexan and the brackets. Lots of vibration in that area, gaskets would help keep her snug and in place.

Paul

Yup, one step ahead of ya' Paul, that's what the rubber is for But good thinkin'!

 

[ndaugbjerg]

Pete,
You've been most helpful so I thought I'd stick my nose in here and give you an update. My 450 is down to frame and engine. Most parts have arrived. The tank and fenders are stripped and ready to prime and paint. The fork lowers, rear brake, and front caliper and bracket are almost ready for clearcoat. I'm doing a "sidewalk" polish on all the engine covers (If you are standing on the sidewalk when I go by they will look perfect); If you are closer than that, well it's a rider. I picked up 50# of soda yesterday and the forcast was immediately changed to a week of rain; Oh well. I'm trying to document the process and have some pictures. I just need to digest BassCliff's instructions on uploading them. I really appreciate all the help and encouragement I've gotten from the forum. The Wiz has been by my house twice with bits of information and encouragement. As I've repeated before, "I want to ride". That's from a Honda commercial but that's OK.
Niels

 

[ndaugbjerg]

Pete,
I ment to ask if you had the ear of the administrator? I just noticed that I've gone from "Junior Member" to "Member". I don't know what the promotion criteria is, but I assume that the next step is "Senior Member". Having turned 72 the last week of February, I relly would like to forego the distinction of being labeled with this Senior nonsense. When I'm ready to throw a leg over my 450 I'd rather not think of myself in those terms. Thanks again; You guys are great
Niels

 

[GateKeeper]

Niels

it's based on post count, once you hit a certain number of posts you are moved to the next designation, if you want to stay at member status, don't post....LOL

and I don't know what the cut off is, number wise, an Admin will be able to tell you this, all forums are setup on how the forum owner wants it.

 

[Good Times]

You become a senior member when you reach 100 posts.

 

[Guest]

Pete,
You've been most helpful so I thought I'd stick my nose in here and give you an update. My 450 is down to frame and engine. Most parts have arrived. The tank and fenders are stripped and ready to prime and paint. The fork lowers, rear brake, and front caliper and bracket are almost ready for clearcoat. I'm doing a "sidewalk" polish on all the engine covers (If you are standing on the sidewalk when I go by they will look perfect); If you are closer than that, well it's a rider. I picked up 50# of soda yesterday and the forcast was immediately changed to a week of rain; Oh well. I'm trying to document the process and have some pictures. I just need to digest BassCliff's instructions on uploading them. I really appreciate all the help and encouragement I've gotten from the forum. The Wiz has been by my house twice with bits of information and encouragement. As I've repeated before, "I want to ride". That's from a Honda commercial but that's OK.
Niels

Nice one, glad to see she's progressing well can can't wait to see a thread on how she goes together!

All it's done here recently is rain, although it's supposed to clear up this week, was ok yesterday.

With all the rain and riding her every day my polishing would be a neighbourhood polish... when you're in someone else's neighbourhood it looks good Really needs a spit and polish this weekend...

Pete,
I ment to ask if you had the ear of the administrator? I just noticed that I've gone from "Junior Member" to "Member". I don't know what the promotion criteria is, but I assume that the next step is "Senior Member". Having turned 72 the last week of February, I relly would like to forego the distinction of being labeled with this Senior nonsense. When I'm ready to throw a leg over my 450 I'd rather not think of myself in those terms. Thanks again; You guys are great
Niels

I think the guys above have answered this for you I have enough senior moments to justify the senior member status... hahaaha

And happy birthday for a week or so ago

 

[Syd]

Gday Pete - nice to someone else online at this hour :-$

 

[Guest]

Gday Pete - nice to someone else online at this hour :-$

Haha yeah Syd... alarm goes off at 4:45 so I can have some coffee then sort things out before an early trip into work... means I get to miss the majority of peak hour there and back

 

[ndaugbjerg]

Thanks guys,
I guess when I get to 99 I;ll have to change my name!
Niels

 

[Guest]

Thanks guys,
I guess when I get to 99 I;ll have to change my name!
Niels

Hahahahahaa only 50 something to go

 

[Guest]

Well the fly screen should be pretty much done, except it's not fitted yet.

My tacho stopped working on the way to work this morning so I wanna check that out before fitting the screen. The cable appears to be screwed in properly each end and it's a brand new cable, so not sure what's up yet, didn't get a chance to check it this avo when I got home from work. Hope to get to that tomorrow.

The positive side if the tacho itself has carked it is that it increases the urgency at which I need to look at an Acewell...

Anyway, onto the fly screen... here's where the brackets were at at the start of the night and the mounting plates for the front as well:



So, first thing was to get out the wet/dry paper, 280 grit, and start working on the brushed look:



There's a definite difference going up to the 400 grit, but you can't really see it in the photo:



I'm happy with that and have left it there. I haven't cleaned them after the sanding at that point either, just wiped with a rag.

Next up, cut the rubber to the general shape:



Cleaned everything with wax and grease remover, masked off the parts of the brackets I don't want to get contact adhesive on, and laid them all out ready:



Contact adhesive sprayed on:



And a bit of overkill, but will work to keep the rubber compressed on the alu. for a while to make sure the adhesive sticks well:



And the brackets ready to roll after trimming the rubber to shape and cutting the holes out:



While letting the adhesive set for a while, I gave the edge of the screen a run around with the 280 grit paper as well to make it nice and smooth, and I don't think I'll need any trim around the outside either.

So this is what it's like fully assembled, and I have nylock nuts on the rear of the allen head screws too:



Overall I'm pretty happy with how it turned out, but can't wait to get it mounted and give it a road test to see if it's really any good or not...

And now I need an opinion...

 

[Guest]

When I went to leave work this avo, the building manager was wandering around the car park and it turns out the ability to park under the building is coming to an end soon as far as he's aware. This means I need to park out the front in the designated motorcycle parks, but given it's Fortitude Valley I'm not real keen doing this and having my battery as exposed as it is.

So, another thing I worked on quite a while ago was some side covers out of 1mm alu. as well.

I got to a point where they were pretty much done, but I tried to make the right one hinged with a lock to try to get at the battery easily and to allow me to make a bit of a storage box above the battery, but I'm just not sure it looks all that good, and I think my lock is quite ugly.

Here's where I got with them and if I continued they'd end up curved over at the top to match the shape of the frame rails and they'd have a brushed look also.

I'm just not convinced it looks right...

My alternative thought is simply to make a cover for the battery box. The thinking there is a hinge bolted to the rear of the battery box with a cover over the top and a bit down each side and a keyed lock at the front so once again it's relatively easy for me to get to the terminals without just letting them sit there exposed to the public...

Anyone got any opinions/thoughts on this at all? I'm not sure how long I've got until I have to do something...

 

[cowboyup3371]

I like the look you did with this but I think it'll be even better if you can paint it to match the bike.

 

[Charlie G]

Pete the fly screen looks great. The side covers I'd have to see in person. The exposed bolts and such detract from the covers. To bad it can't be hidden some how.

cg

 

[ndaugbjerg]

Pete,
The lock looks fine but I am curious as to how many Foster's you had before you mounted your front fender? And since you are the 450 Guru, I have a question. Have you ever run across a remote oil filter conversion kit? I'm not lazy but at my age I don't have as much time as you guys. And from my many years of experience, I learned that those things that are the easiest to maintain get the most maintenance.
Niels

 

[spyug]

Pete, I'm with Cowboy. I think the side panels need to be painted, otherwise they will be fine. I notice also that the struts attaching the front fender are unpainted as well and, too me, it draws the eye right in. Perhaps they should be painted too, maybe black even.

Excellent work on the flyscreen, we IT Geeks are creative at times aren't we .

Now I take it your office is in a bad part of town and batteries get lifted all the time? Any fear of outright theft or vandalism?

Since you are almost done with her what's the next project going to be?

Let us know how the screen and side covers work out.

Cheers,
Spyug

 

[Redneck]

I have to agree with Cowboy (imagine that the Redneck and Cowboy agree) okay and the Canook...lol. Painted primary black for sure then maybe some kind of red accent or something like a 1-2" band of black round the outside and red in the middle to match your paint then go get the 450 side cover badges and mount them on the cover.

I like Spy am wondering what you will be working on next or has the significant other banned you from over obsessive projects.

Paul

 

[Guest]

I like the look you did with this but I think it'll be even better if you can paint it to match the bike.

Hmmm... painting hadn't even entered my mind... I need a quick turnaround though so I'm not sure if I'll get time to get it done...

Pete the fly screen looks great. The side covers I'd have to see in person. The exposed bolts and such detract from the covers. To bad it can't be hidden some how.

cg

Cheers Charlie, I'm still surprised that the fly screen looks as good as it does, just hope it's at least as functional as it looks.

I agree on the exposed bolts, that's my main issue with the side covers. If I could weld aluminium that would change things, and I think this is once instance where I wouldn't like to trust JB Weld either.

www.alumiweld.com would be an option, but again it will take a few weeks to get the rods... an option though.

Pete,
The lock looks fine but I am curious as to how many Foster's you had before you mounted your front fender? And since you are the 450 Guru, I have a question. Have you ever run across a remote oil filter conversion kit? I'm not lazy but at my age I don't have as much time as you guys. And from my many years of experience, I learned that those things that are the easiest to maintain get the most maintenance.
Niels

Thanks Niels... what's up with the front guard? No Aussie in their right mind drinks Fosters either

Haven't seen a remote filter conversion at all actually, but then again I haven't looked either. I'm sure a lot of our GS' share the same oil filter setup though, so if something's available for a 4 cylinder, it might be able to be retro-fitted to the 450...

Pete, I'm with Cowboy. I think the side panels need to be painted, otherwise they will be fine. I notice also that the struts attaching the front fender are unpainted as well and, too me, it draws the eye right in. Perhaps they should be painted too, maybe black even.

Excellent work on the flyscreen, we IT Geeks are creative at times aren't we .

Now I take it your office is in a bad part of town and batteries get lifted all the time? Any fear of outright theft or vandalism?

Since you are almost done with her what's the next project going to be?

Let us know how the screen and side covers work out.

Cheers,
Spyug

Thanks Spyug, number two for paint... hmmmm... The front guard mount/fork brace is basically brushed aluminium, and those photos with it in the garage make it artificially visible by the camera flash. I think it fits in when it's in natural light personally...

And yes, we can get creative indeed Very happy with the screen!

The area the office is in is not the greatest, and we've had a homeless guy bashed to death outside the building as well as a number of other things over the years. It's better than it used to be and I'm probably paranoid but having that battery exposed I feel is probably just too tempting for some types, so figured I'd be best safe than sorry...

The next mini project after the screen and covers or battery box will hopefully be a rear carry rack modelled on the stock sports rack which is made out of unobtanium, but the next real project will be the Ducati Cucciolo engine sitting here.

My cunning plan that may be not so cunning is to get my wife to agree to a dual car port out the front which will free up one side of the garage (her Peugeot will have to stay in).

Once that room is available, I'm hoping the Ducati can fund the next bike... hopefully a 750 popup Katana...

I have to agree with Cowboy (imagine that the Redneck and Cowboy agree) okay and the Canook...lol. Painted primary black for sure then maybe some kind of red accent or something like a 1-2" band of black round the outside and red in the middle to match your paint then go get the 450 side cover badges and mount them on the cover.

I like Spy am wondering what you will be working on next or has the significant other banned you from over obsessive projects.

Paul

Number 3 for paint! Thanks Paul... common theme here...

If I do go paint Paul, it definitely won't be anything fancy like that as I'm struggling to think of how I'll get time to even do plain black...

See above for the next project too

Thanks heaps for the feedback guys, I'm going to give this some more thought, but I might end up in a completely different direction yet... I'm still entertaining just enclosing the battery box as is...

I think though if I was to continue with the sidecovers that I would need to start from scratch so they don't have bolt holes, and get some attachment points welded on instead, and I think if painting is the answer they'd just have to be a semi-gloss black to fit in with the rest of the bike...

 

[Matchless]

Pete,
Your bike looks great man! If it works for you leave it as it is and ride!

Just a quick question I need to order something from Boulevard Suzuki and I cannot seem to get it sorted and they are not replying to my mails.

I seem to recall that somewhere in these thousands of posts you mentioned how it works when ordering internationally from them.

Much appreciated.