$270 '78 GS1000EC Project (Frankenstien Re-build)

[Mr.Midas]

Long overdue. Started this project last May in hopes that I'd have it on the road before fall, but construction-work and college-work took up more time - and then, more work when fall came.
Now, after returning home about 2 months ago from 5+ months of work out of state, I finally begin my project thread...(I promise not to be so long-winded in subsequent updates)

About me:

Student(working towards a BSBA for the time being); Self employed(construction, general contracting, repairs- structural, mechanical, electrical); Avid hobbyist/do-it-yourselfer (Rebuilt RX-7, electronics, computers, firearms, equipment, woodworking, ect.)
I've owned one motorcycle before this, a completely stock(if it ain't broke, don't fix it) Yamaha Seca XJ600s, and loved it(all but the 4200rpm buzz from the front fairing that I never found a way to stop, short of removing the fairing altogether. It was nearly a year after selling the Seca when the bike bug really began to bite hard. I was already set on finding something simple and perhaps a little larger for longer rides(and perhaps more spirited riding) A GS model would have fit my criteria easily; although, I hadn't really considered one. There weren't any around locally and I wasn't that well informed on model/engine histories much then either. I sat on the fence for a while watching the classifieds for a decent used bike that fit my needs & budget... Perhaps a Honda or another Yamaha needing some new tires, a carb job, and a little paint?

That's when I stumbled on this old GS and decided a real project bike was the way to go, and began hunting for what parts I could find(and budget) to put it back together in a slightly sportier, intimidating, and updated configuration... and then dreamed about riding all that summer long!
​

The Bike:

1978 GS1000EC with 28,000mi on the clock. Poor condition overall. Not running when purchased. The motor turned freely(but the crankcase was dry?) Missing: Gas tank, Side covers, Seat, Most of the intake, Rear signal lights & brackets, Little bits and pieces(some were stashed in a cardboard box)
​

The PO had been the second(or third) owner, had stored it away around 12 years ago when a medical condition prevented him from riding.
It was in decent restorable shape when he took it to a "guy from church" who was supposed fix the old girl up for him(using a few cosmetic parts from a donor GS he had picked up for cheap)... The guy soon after stopped answering phone calls and then completely disappeared(more likely just didn't want to be found). When the PO and his son went to get his bike back they found the bike had been picked for parts and the donor bike was no where to be found.

After all that the PO was still regretfully selling his old bike. He was starting a kitchen remodel project and he already bought a new cruiser to satisfy his riding needs - and, I think it was to much for him to see the bike sit there in the condition it now was in.




The beginning(minus the crazy huge road cruiser fairing with built in radio):

 

[Smokinapankake]

Wow! Dude offers to help him fix er up, then takes parts off it to fix up his own bike, or just parts them both out for a profit, then disappears! Holy crapnuggets!
Maybe I'm sheltered, but I would not have seen that coming from an inch away!
Good luck with it!

 

[tkent02]

Nice frogs, too bad about that church guy, you have to watch out for them.
They seem to think this kind of crap is OK as long as they ask forgiveness or say some Hail Marys or something.

 

[Mr.Midas]

I've learned to look at religion in general as being at a individual/personal level, and only a few traits can be considered common among like-minded believers. Dishonest people are everywhere, so I don't fault the church this guy was going to. The problem lay solely within that individual, and according to the Bible, each individual(regardless of any group they belong to) must give and account of their deeds before the judgment seat.(2 Corinthians 5:10)
There's a big difference between someone who just shows up at a building Sundays to feel good(and thinking they're top taco just for showing up), and a person who reads, understands, and strives to live according to words such as, "Do unto others as you would have them do to you" Mat 7:12.



But I digress from religious musings for which only some have an interest, and return to the task at hand(which should interest most here):

Where was the oil leak? About a weeks worth of leakage on the shop floor(time to raid the kitty litter):

A cold/dry (and probably slower cranking than normal) compression test revealed 122-121-110.5-121.5 psi compression. Seems promising... After putting in some fresh oil, setting up a fuel bottle, and connecting a battery(after looking over the harness and insulating a couple bare wires), She actually cranked and ran for short spurts.

I was expecting a cloud of smoke, but none appeared! After that I parked the bike inside and resumed a busy work schedule, returning a few days later to find about 4oz of fresh oil on the floor.

After cleaning up case with scrub brush and engine degreaser I found this:

What it is, is a small crack radiating vertically beside a perfect little circle galled into the case, right behind the lower left mounting hole. (Someone had torqued a long bolt through the mount tab and into the side case!).

 

[Rover]

Is the engine toast? What's your plan?

 

[7981GS]

The scratched steel tube is the frame and you did not rotate the picture so that we could put in into perspective?
Is that the case? You do not have a "rotate" option for your pictures?
I am trying to figure out just what is cracked and where it is on the bike.

Daniel

 

[Dodik]

my guess is this is right by the brake pedal?

 

[Adler]

Starter drain hole?? Its hard to tell where that picture is on the bike.

 

[7981GS]

Under the bike?

Daniel

 

[chuck hahn]

Obviously from the bottom view based on the drop of oil on the case ridges..and on the right side just behind the pipes..

 

[Adler]

Cant be certain from the closeup picture but heres a thread about the mystery hole.

http://www.thegsresources.com/_forum/showthread.php?t=133174&highlight=mystery+hole

 

[Mr.Midas]

Sorry about the weird angle. I was taking that picture laying on my side and twisting to get a clear shot directly under the lower left engine mount.

The crack appears to be a little over an inch long, and almost disappeared after sandblasting. I'll have a better pic up soon. After blasting I left the sealed up motor to sit, so the crack hasn't been fixed, yet.

I was hoping the motor would be good for another riding season or two before needing a proper rebuild. I've seen guys patch big holes in dirt-bike cases with JB-Weld, and I've had very good luck with it in the past(works great for bedding rifle actions, btw). I know it's still not an ideal fix, but I really don't want to get into the motor until I know it needs other internal servicing done.

Maybe at that time it would be best to just pick up a good used bottom case instead of trying to tig weld it?


Initially, I was going to go as cheap as possible to get it back on the road - Bobber Style . But reason got the better of me and quickly changed my mind.

So my plan is/was to: Update the electrical/ignition components for increased reliability; Brace and clean up the frame; "update" the rear end with swingarm swap and a little extra height; Sporterize the handlebars and foot pegs; Upgrade the front brakes; Fit a slightly larger gas tank from whatever I could find for cheap and hopefully make it look good on the bike; Fabricate my own seat and side panels; Pods & 4-1 exhaust; and generally clean up/fix/modify/paint the varied parts for the best form and function to suit my needs. For a seemingly cobbled-together project, I hope it won't be completely unrecognizable as a GS or lack decent continuity (aesthetically and functionally).

But this is my first real "project bike" so I don't expect it to be absolutely perfect the first try. I do have some skill & know a few tricks, but I'm still learning a lot as I go.

 

[rustybronco]

After cleaning up case with scrub brush and engine degreaser I found this:


What it is, is a small crack radiating vertically beside a perfect little circle galled into the case [not a hole*], right behind the lower left mounting hole. (Someone had torqued a long bolt through the mount tab and into the side case!).

To Me, what it sounds like, is some one put a longer bolt through the frame mount and it contacted the side of the engine case; cracking it.

if it were me, I would lean the bike to the right side or drain the oil, clean and degrease the area, sand it, then JB weld the cracked area.

*emphasis added

 

[7981GS]

If the engine is out of the frame,
just take it to a local bike or machine shop and have them WELD it.
Should only be the "shop minimum charge" of about $15.00.

Daniel

 

[Smokinapankake]

I vote weld it. In the current condition (sans body, almost naked, actually), a pleasant afternoon o wrenching should have that engine free of the frame.
But - it is a heavy bugger so you might want to enlist the help of a few strong back, weak-minded friends to lug that lump around.

The advantage, obviously, is a repair done properly, and also the ability to inspect areas otherwise difficult to see.

Should you go the JB weld route, be sure everything is clean. CLEAN. CLEAN!!!!! Otherwise you're just shooting yourself in the foot.

 

[TheCafeKid]

Those cases are so porous they're very difficult to weld successfully. I agree it's worth a shot, and I can't really see how big the crack is, but you may find it's a permenant fix. Then you also may find that even after welding the oil will seep through the weld. Worth a shot for sure if it's only a few bucks (less tha $50) to have it done.

Can't tell from that pic but agree with Dale. Likely that's one of the mounts that uses the little teardrop nuts on the back side. A pain to get back in too. But someone probably used too long a bolt and just kep cranking on it til it was "tight" and had punched into the case....

 

[7981GS]

Possibly a better picture of the damaged area:

TCK is probably correct. Someone, installed a bolt that was WAY too l-o-n-g.

Daniel

 

[Mr.Midas]

Wow, you guys are good! Great deductions and input very appreciated. Here is a better shot of the crack's location(I'm pointing up behind the mount hole inside the hollow area where the teardrop nut goes)

To weld it all the way up I'd need to get at the backside and I think to even hope for a clean leak-free weld it would need a proper degreasing, bake in the oven, and then another scrub with soap and water. The bike was apparently set up for cruising and wasn't ridden hard, so it should be sound enough internally to forgo a rebuild this season at least. My shop space is a little limited, so when I need to do motor work I almost have to "retool" and setup a clean environment to work in. Most fab work must be stopped to keep the dust away(and even then it seems to never fail that someone leaves a door open while making dust outside)

 

[Mr.Midas]

Catching up on progress. Most of this was done through last summer:

The tank from a '77-'78 CB750A I picked up for $52.50 shipped. Ready for fitting modification.

Cleaning up the rear frame and setting up the 01-05 GSF1200 Bandit swingarm which I picked up for $85(just recieved the bushings and lower shock mounts made at a local machine shop for $215)

More pics to follow(after I get some sleep)

 

[Mr.Midas]

Setting up the rearsets from 03-04 GSXR1000 - Left with shifter linkage, Right with MC, light sw, Caliper & hanger. Total: $89.55 shipped.

Ended up with about 7.5" inches behind and maybe .5" higher than the stock footrests.





Time to recycle this tubing!

The bent portions worked nicely to brace up the front with revised coil mounting. Coils with good ends are from a Honda VT750 $20 + shipping with other parts. (those crappy welds were cleaned up later on after I acquired more practice and a better helmet)

Bracing in the frame(can't remember what that location is called atm) and passenger footpeg mount tabs set. Brackets are from an 08 Kawasaki ZX10 @ $25 + shipping with other parts.

Still need to upload pics of the rest of the bracing /w front gussets, upper tube boxed gusseting, and X-brace seat mount above the rear wheal...



Fitting the Gas tank: New rear mounting plate fabbed and tacked in place(if you look closely, you will notice the boxed gusseting on either side of the upper tubes.)

Had to make some clearance for fork tubes and upper tree: Trimmed back the front and removed a little crimping(challenging sealing it back up. De-rusting the inside first probably would have helped)





Rear mounts attached and tank mounted after some clearancing work on the underside. Surprised that the neighbors never complained about the late-night racket I made.
Also you can see the test fit '02 KTM 300 Aero-tapper Bars with riser adapters I picked up for $50.00.

In Primer after some sanding/filler work.

EDIT: The tank was striped down on the topside with chemical stripper before paint-work. Also the inside was thoroughly cleaned and treated with phosphoric acid based rust-converter(got the kind from kleen-strip this time and it worked as well as any other I've used), and to prevent the tank from rusting up again, it was lined with Red-kote. Also not pictured is the new petcock bung which I welded in aft of the original.