1984 GS1150ef rebuild!!! renew!!

[wyly]

Surprisingly difficult to remove the paint on the tank. The clear coat resisting aircraft paint stripper. A wire brush mounted on my drill had to chew through the clear before the stripper could remove the paint. I had planned to use a clear to prevent the tank from oxidization which would take place overnight but I found a product used by machine shops that stops the process, Gibbs. A little added to a paper towel and rub it in, done. I only need to reapply it if I have a fuel spill or if I need to buff out a scatch.

 

[dorkburger]

Not sure if one needs to join to check out the thread..

https://oldskoolsuzuki.info/forums/...-will-end/page/3/?tab=comments#comment-168899

 

[wyly]

Not sure if one needs to join to check out the thread..

https://oldskoolsuzuki.info/forums/...-will-end/page/3/?tab=comments#comment-168899

Ah you found my thread there.
It took a while before I got in, OSI website wouldn't recognize my email address for registration.
Following some of the project threads on OSI has encouraged me to raise the bar as to what I can do. Though realistically I'll never come close to many of those builds.

 

[wyly]

For Charles who was curious as to how I made my tail cowl/ solo seat conversion I break down the process.

I didn't know if I would be successful so I bought a spare pillion seat with a torn cover for $20. I took off the seat material to hopefully wrap the future back pad, getting the matching dark blue of the seat would be impossible. I wrapped the pillion seat in packing tape being careful not to distort the original shape by wrapping it too tightly.


the next step for some reason I can't upload the photo GSR rejects.
I bought rigid florist plant mounting foam from an art and crafts store(Micheals) laid it on top and sanded it down until the contours matched the pillion seat then extended the lines upwards to the height that made it level front to back.
I wrapped/taped that in place with more packing tape and then a layer of duct tape to make firm surface.
Next I rubbed bees wax over the entire surface so the following fibreglass wouldn't adhere to the tape.

 

[wyly]

The finished height was no different than the oem in the rear. At his point the pillion seat was removed and I added 3-4 layers of fibreglass for strength, reinforced areas I though would be likely mounting points, filled in some low spots, straightened some lines. I suck at fibreglass it took me awhile, it was important that I get it as smooth as possible so I wouldn't need much bondo to hide dips and blemishes.

View attachment 61822

 

[wyly]

Tried uploading a "single" picture of the prime stage but GS Resources rejects it telling me I'm only allowed one photo

back pad was cut from I had left over from my CBX seat project. Cut and shaped to fit the space above the drivers seat, I cut it larger than required so it would expand once inside it's shell.
this photo was rejected as a "multiple photo" earlier...and now it's not.

 

[wyly]

Until I come up with something better here's how I attached it to the seat for now.
Originally it was attached to the pillion base but there were a number of issues with that method. Attaching the cowl to the seat solved a several of problems at once and it all comes off with only the oem key.
This could all change in a years time, I've had thoughts of making an aluminum cowl or an auxiliary fuel tank. Or tucking a NO2 system under the cowl. Or a new home for the fuses, reg and battery. Or leave it as is and I can easily put the pillion seat back in only ten minutes.


Quite a disastrous attempt at adding photo's, I may be hopeless with IT but the forum design isn't making it easier.

 

[wyly]

Frustrated by the awkward frustrating requirements of the forum for posting photos I shifted my project thread over to OSS. I completed the fairing conversion transformation to alloy. A steep learning curve and mega frustration but I got there, 8 months. It's solid, quieter and has better air flow than the oem it works better than I had hoped. Downside, it does get a lot of attention when I'd prefer not to be noticed.

click to enlarge

 

[wyly]

Never figured out how to rotate photos either, sorry

 

[wyly]

Final version I went back to my red fibreglass tail cowl, the extra splash of red balances the front imo. The alloy cowl is stored away if I want go back to it later.

Of coarse my builds are never really completed, modifications are always in progress. Another 2 years before I've reached the final version in my head but that could change again.

 

[Grimly]

Lovely job.

 

[wyly]

I'm not even gonna ask how you did that Grimly but thanks

 

[wyly]

It's been awhile since I've updated my photos for my efe project. Still vexed by an inability to post large photos and more than one image per post.

 

[wyly]

can't get them in the proper orientation either.

 

[wyly]

Thought I was done almost done with converting the plastic to alloy at this point.

 

[steve murdoch]

Robert, can't help you with the tech side but i like how the bike turned out.

 

[wyly]

Robert, can't help you with the tech side but i like how the bike turned out.

I've completed even more than in those photos but I really struggle with IT, the forum won't even upload the latest photos, no idea why they're in the same format as the others. The only parts now still in plastic are the rear fender and inner fender.


I'm really surprised how much attention the alloy appearance gets, it's not unusual for me to park somewhere and come back to find other riders checking it out. Always a lot of questions to answer. "Why?" "What type of bike is that?" "How long did take to build?" "Are you an aviation metal fabricator?"
And I'm somewhat embarrassed as in my opinion it's still rough and a long ways from completion, at least another 2 winters of work. This winter I'm boring the block and installing Katana sleeves and pistons for a healthy boost in HP and torque, while engine is out painting the frame and maybe begin the electrical upgrades.