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Cafenated GS1000

  • Thread starter Thread starter bhppy101
  • Start date Start date
B

bhppy101

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Ok......I just bought a 1980 GS1000 in almost mint condition tonight \\:D/ I was going to start on my cb750...but since this forum seems to participate more....I decided to do the GS1000 first!

I plan on converting this into a monster Cafe racer. I'll post a pic of what she looks like tomorrow in the daylight....and if you guys want....I'll try to do a complete step by step of the total makeover. Hopefully this will only take me a couple of weeks to complete! with a lot of late night work and lots of coffee! :shock:
 
Funny, that's what I said when I bought my GS750E.......

Hope you have better luck than I!
 
GS1000 cafe would be awesome, especially if you could yank some weight off the bike. Good luck with it.

I got halfway there with my 750:

medium.jpg
 
Here is my GS1000....I picked it up friday night....first thing after I unloaded it....I took the carbs off for cleaning and inspection....gave her an oil change....checked all of the plugs and fired her up. Runs and idled PERFECTLY! I took it out on a quick spin (now 2am....lol.) and man!!...she rode like a bat outta hell!

The before:


 
Saturday:

I took her out for a few hours so that I can get a feel for how she rides before I take her apart.

Took off the windshield, seat, taillight and cowl, blinkers, and I had to get rid of those huge bars! I put some smaller ones on it for now (until I get my clubman bars in).

I removed the original pinstriping off the tank and used some black pinstriping to mark the area that I am pounding out for knee inserts. This gave me a good guide to keep my hammer. I used a flat body hammer on the bottom to get the line of the tank straight and flat. Than I used a pin and ball hammer to gently shape the inside of my mark to get that concave scoop look. After I'm satisfied with both sides being symetrical....I will smooth it out with some filler.




 
Chopped the rear and tabs off and put my clubmans on. I halso did a little more pounding on the bike.



 
This guy is a madman!
I sure hope he paid alot for that bike...
Otherwise I'm gonna be really jealous.
and if you guys want....I'll try to do a complete step by step of the total makeover.
Click to expand...
Definately YES! We love those. Rock on.
 
justin caise said:
This guy is a madman!
I sure hope he paid alot for that bike...
Otherwise I'm gonna be really jealous.

Definately YES! We love those. Rock on.
Click to expand...

A mad man I am!....lol

OK....Time for some fiberglass!!!!

I first cut a template for the base of the seat out of 1/2" ply using the shape of the frame.....I then got some blocks of green plant foam (got it at Michaels arts and craft store) This foam is usually used to stick fake plants in and can be found at any arts and craft store. I like using the green foam because it is easy to shape. I use a turkey carving knife and slice away like I do at Thanksgiving dinner..:-D I use 3m spary contact adhesive (bought at home depot) and spray both the wood and the foam where they will be contacting together....I let both sides dry for a couple of minutes....than press the foam where I want it. Be sure that you place it in the exact spot....because you only get 1 shot. Once the two pieces make contact with each other...there is no turning back![-o<

 
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I cut a general template for the back of my seat cowl and glued it to the back of the seat.....I used some 1/8" fiberboard scraps for this.

 
Now....I cut and sand down the angle on the front of the cowl so that i can create a front template... remember....these templates are just a guide to shape the foam in a symetrical fashion.

 
Very impressive work. I am interested in how exactly you are going about hammering your own gas tank?!? Anymore info/pictures/specifics on that would be appreciated!
Also, a step by step makeover conversion would be sweet!! I want to see/hear all about it. I am currently doing almost all of the exact same conversions to my gs750! I thought about doing my gas tank fiberglass, but I am interested to see how your 'hammered' tank turns out!
Keep up the good work!
 
Thanks! Albert

I'll be working on the tank as soon as I get done with the seat. Stay tuned.

After I was satisfied with the general shape of my seat...I masked it all off so that I can lay some fiberglass matt and resin on it.

I layed about 4 layers of matt down.......I'll let this dry...and in about 1hr...I'll lay down another 3 or 4 layers of matt so that the seat will be as strong as steel




 
i like the shape of that new seat!

are you using the foam/plywood/masking-tape as a mold to build on top of or a core that will remain in the seat on the final piece?

just wondering the best way to make it work...for when I start mine.:D
 
pozzi said:
i like the shape of that new seat!

are you using the foam/plywood/masking-tape as a mold to build on top of or a core that will remain in the seat on the final piece?

just wondering the best way to make it work...for when I start mine.:D
Click to expand...

Thanks....I made an exact fit on the rear for the tailight that I will be using...

After I sand it down and smooth it out with filler....I leave the ply base on the seat (just makes it that much more rigid)...but I cut some ply at the rear cowl to get to the foam. I just pour some acetone in it and it melts the foam away. This is called the lost foam method.

I just laid a few more coats on and it will be ready to smooth out and prime. I'll shoot some pics later tonight.
 
how do you 'mount' the final product?? Is it a removable seat?? Or do you actually glass it to the frame?
 
I weld some steel tabs to the frame....and bolt the seat down
 
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Here's a few pics...I filled it with body filler and smoothed the seat out. than I gave it a few coats of filler primer to fill all the sanding marks. now I just need to wet sand it with 400 grit to smooth it out some more. After that...I'll prime it again with some sealer primer and wetsand it again with 800 grit....Than it will be ready for paint and clear.:)



 
I painted my seat with a black base coat....all I have to do is make my fiberglass seat pan for my foam and vinyl.

I started on my tank tonight. I did some more pounding...than I filled it with poly filler as well as the Suzuki badge inserts. The pics you see are with the filler before sanding.




 
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