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'80 GS1100E rebuild

  • Thread starter Thread starter cavehamster
  • Start date Start date
Slow updates at this point, trying to stagger purchases so I can budget them out a bit, haha.

Still waiting for gasket kit and small parts, but realistically don't expect the OEM parts in for another week and a half. I went with the gasket kit that partsnmore sells, we'll see how that works out.

Went by the auto machine place today. The crank case was out of the wash tank, looking pretty good. I'll need to hit the outside of it with a walnut shell blaster or something to get it good enough to paint, but it sure looks good otherwise.

The guy still has the crank. He's headed off to get some chrome rod today to make up a measuring jig, told me to come by tomorrow to see how he is doing. The quote right now for the 4 welds is $50 if the crank is not twisted. So, I'm happy.
 
Was that repainted? I only know of red and silver 1980 models.But hey it's A 16 valver thats all that matters.Have fun with it.
 
new bob said:
Was that repainted? I only know of red and silver 1980 models.But hey it's A 16 valver thats all that matters.Have fun with it.
Click to expand...

I'm assuming the black that it was when I got it was not original. When I was sanding the tail piece, I found evidence of old stripes under the black paint, so... I really have no idea what it was originally.

I'm repainting it a Chrysler color, Electric Blue Pearl Metallic, which apparently came on some models of the PT Cruiser. Eh, whatever, it's a pretty color, yeah? Hehe...

I still gotta do the side panels (and buy one side panel since the left one is broken), and figure out what I am going to do with the front end. The square bucket is kinda nice as it hides the wires, but I'm not going back with stock clocks so I've gotta do something, maybe a huge round headlight? I don't know yet. Oh, and the front fender too, but that can wait until I do the front end swap...
 
TheCafeKid said:
$80 to weld the crank huh? That's a deal. Till it goes BOOOM! ;)
Click to expand...

$50 man!

I'm not terribly concerned at this point. If it does, then I'll just build another one. I'm sure I will be building more in the future anyway ;)
 
Ha! I am still alive!

Been slow over the winter, but I have been slowly gathering parts. The crank came back from the machine shop today, after being there for almost 3 months. Nice guys, but busy. They ended up welding it for $56, and they made sure it was true as well. Looks like a pretty good job.

I also got the cylinders honed and a set of stock rings from someone on the forums, so I'll be wussing out and sticking with stock for another season.

Picked up a cheapie sandblaster and some walnut shells, so this weekend is probably going to involve me roughly bolting the engine together so I can seal it up and get it prepped for paint. With any luck I'll have it running in another week.

Still need to finish the rear tire conversion, but at this point the only big thing remaining is to CNC up some shock mounts and have the sheetmetal shop weld it up for me.

Getting closer for another fun season of drag racing, I think.

I gotta get the seat in shape this time around. Anyone have any suggestions for somewhere that can re-upholster on the cheap?

I'll have some more pictures soon. Still need to paint the side panels (and get a new one for the left side), but the tank and the tail are painted up and looking great.
 
Got the engine walnut blasted. Next time, I will spend a lot more time making a better booth. I kind of half-assed it and it was annoying. But man, it came out looking good. I still need to wash the dust off all the parts, re-tape, and paint, but hopefully that will all happen this week.

I got a line on some front forks off a 06 or so GSXR for pretty cheap. If they are too short, I'm pretty certain I can turn a profit on ebay and find some other ones, but... at least moving forward. Need to find a front wheel now too.

Wheee!
 
Engine is painted!

The block was jet washed at the machine shop, and then I degreased everything, and shot it with walnut shells. Those things work like a champ! I need a better spray booth, though.

I cleaned the aluminum with a etching cleaner, then shot a thin coat of primer/sealer on everything. I heat tested the primer under a heat lamp to 450+ degrees F and it didn't even bat an eye, so hopefully that will not be a failure point. I was concerned with paint adhesion, which is why I went through so many steps. The final paint is just some basic satin black bbq paint. It turned out a tad more brown than I would have liked, but we'll see how it does once it get hot a time or two. All else fails, I'll do this again sometime.

The paint is no more than a mil or two thick. I'm also in the process of sanding the edges of the fins down to finish it off.

I have better photos, but I left them in the camera. Maybe later I will add them ;)

Primed:

IMG_9207.JPG

IMG_9206.JPG


Finished, except for the sanding of the fins:

IMG_9201.JPG


IMG_9211.JPG


This is a horrid shot, but this is everything else. Still shiny here, it all finished out much more satin:

IMG_9219.JPG


And, I just picked up a set of throttle bodies off eBay, woot:

%21Bnv%28PWgBmk%7E$%28KGrHqIOKjgEtjl4lFGJBLkvtfPqiQ%7E%7E_12.JPG
 
Got the engine into the garage this week, and I managed to get the case shells together tonight, hurray!

Here's the welded crank:

IMG_4245.jpg


I'm pretty happy with the paint. Trying to be careful with it until it gets baked on harder.

IMG_4248.jpg


As per advice, I put the tranny and crank into the top half:

IMG_4268.jpg


And... assembled!

IMG_4276.jpg


I did mess up a bit... looks like TriBond eats my paint a bit, eep!

IMG_4280.jpg


Much larger images are here

With luck, I can finish the engine assembly tomorrow, and get the cams dialed in, engine in the frame Friday, and final testing on Saturday in time to get it to the drag strip Sunday. Hopefully. Wish me luck.
 
Worked on the top end. I cut up a socket to use as a keeper installer. It worked, but was probably not the safest way I could have done it.

IMG_4286.jpg


It was quite the chore to get the jugs on, but I managed:

IMG_4290.jpg


Finally got the top end on and together.

IMG_4300.jpg


Made a degree wheel, but ended up just going stock anyway, for now.

IMG_4313.jpg


Thank goodness for my engine hoist, it makes one man installs pretty easy.

IMG_4319.jpg


And it's in!

IMG_4324.jpg


I like the all black treatment so far. Tomorrow, I shall get the electrical and body work on and hopefully it runs ;) I'm planning on breaking it in proper at the drag strip on Sunday with some easy runs.
 
Nice Pics. your the man keep on crackin. Cant wait to see this thing done.
 
Looking good! I'll be doing the same here in a couple of weeks.
I was supposed to pick the upper case, piston kit, worked head and cylinder up today but someone I know tweaked their neck.
 
It was a good day at the strip today. Got the bike tuned up and gently broke in the rings over about a half dozen runs before really getting on it. Best time for me was 11.60, down from last year's 11.68. Now that the engine is broke in and working good, I can start working on modifying the stock items.

Here's a couple more photos of the bike for your viewing pleasure.

IMG_4510.jpg


IMG_4505.jpg


IMG_4502.jpg
 
If you are going to use it more for the strip, I would lose the airbox & rejet for that. It will gain you a tenth or two in ET reduction & about 3-5 mph in the quarter. Also, is it geared so you are at 9500 in 5th gear at the finish line? This is all assuming you are racing 1/4 instead of 1/8 mile. Ray.
 
rapidray said:
If you are going to use it more for the strip, I would lose the airbox & rejet for that. It will gain you a tenth or two in ET reduction & about 3-5 mph in the quarter. Also, is it geared so you are at 9500 in 5th gear at the finish line? This is all assuming you are racing 1/4 instead of 1/8 mile. Ray.
Click to expand...


Thanks for the suggestion. The plan is that now that the engine is proven to be working well and the broke in, I will be moving towards putting fuel injection on it via MegaSquirt, so the airbox and etc will be gone pretty soon.

Current gearing has me cross the 1/4 at 9500 at the top of 4th, 16T front sprocket and I seem to have forgotten the rear. What do you think, what should I be aiming to cross the line at?
 
15/46 will get you close to being at 9500 in 5th gear at the finish line. Even 10,000 at the stripe will be ok as long as the jetting is RIGHT! Ray.
 
rapidray said:
15/46 will get you close to being at 9500 in 5th gear at the finish line. Even 10,000 at the stripe will be ok as long as the jetting is RIGHT! Ray.
Click to expand...

OK, I'll give that a shot. I was headed more in the direction of aiming for less shifts, but it would make sense that you would have a better hole shot and stay in the power band better by getting through all the gears.
 
Busy last week and didn't do anything to get ready for racing Sunday, but I went anyway.

Good news is that it felt like it was running strong. Bad news is that I ended up with issues, hah. Turns out I put the wrong oil in, and now I have a slipping clutch, but that can be resolved. The other issue is that the bolt on the end of the crank on the rotor side came undone, the rotor and starter clutch slid off a bit, and ground against the side cover. I found out when the bike wouldn't start. I don't really see any real damage, maybe some pitting on the taper shaft and the mating surface, but nothing that should prevent it from being OK when it goes back together.

Yeah, I overlooked the torque on that nut, grrr.

Anyway.. still lots to do, hope I can find some time between now and weekend after next to have a little done, hah.
 
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