FAUX 78 Skunk 1100 Project

[Gregory]

Ok before I start this thread let me apologize to the purists, but I just prefer the performance of the 16 valve, but the looks and riding style of the gs1000.

I of course have started tearing into this project BEFORE asking for advise.

I have a donor gs1000 frame and I have an 82gs1100e.

Thanks to gmansyz, I was alerted to the fact that the frames are practically identical except for the cosmetic tabs.

I have cut all of the body work tabs off of the 1100 and will weld the 1000 body tabs on the 1100 frame.

Before I start welding things on I wondered if anyone has done this before?

What was the best practice for relocating the petcock or lowering the carbs?

Alternatively, would 29mm smoothbores be as good on this bike as the stock carbs?

...and last but not least, does welding on a frame while the electronics are on the bike damage the electronics? I know I will end up pulling everythi8ng off to clean and paint the frame, spiff up the engine etc.... but would like to tack everything up before then.

Here are pics of the skunk parts sitting on the nakedly tabbed 1100 frame.

Also, I am saving all the tabs with the 1100 bodywork in case there are any out there that want to covert a gs1000 into a FAUX gs1100ez

 

[Guest]

Why not just stuff the 1100 motor in the 78 frame , swap the swing arm , that way you can do the bearings while it is apart , and swap forks if you want the 1100 brakes ect. that way all sub assembly's get looked at and serviced while apart.I believe you just have to lift the back of the tank alittle to clear the valve cover end caps

 

[Rob S.]

Only two Skunks, and you call yourself a Suzuki rider?

 

[Gregory]

Only two Skunks, and you call yourself a Suzuki rider?

I actually have another skunk out in the shop that is ready to fire up and sync the carbs... this tank is off of it...but I am getting another tank.

 

[Gregory]

Why not just stuff the 1100 motor in the 78 frame , swap the swing arm , that way you can do the bearings while it is apart , and swap forks if you want the 1100 brakes ect. that way all sub assembly's get looked at and serviced while apart.I believe you just have to lift the back of the tank alittle to clear the valve cover end caps

The 78 donor frame has been wrecked and welded, plus I don't have a title to it (would cost $150 to get one)... this 1100 is titled tagged and insured.

 

[Gregory]

Well since no one had any input I assume I didn't have enough pics, didn't explain well enough, or no one has ever done this before.

I should have mentioned that the first test fitting pics of the bike DID NOT have the petcock on the tank. Here are pics that show that.

When I put the petcock off of an 1100 tank in the 1000 tank it comes much closer to fitting.

Here is a picture that shows when the tank is positioned where it would be on the 1000, the petcock hits the carb causing the tank to ride too high.

Here is a picture with the tank moved back toward the seat about 3/4". The petcock does not bump and tank sits flat, but is too far back into the seat area. Other options may be to modify the seat to fit, or move the seat and tailpiece back.... but I don't like that option as well as moving the petcock.

Here is a picture of how the tank has to sit too far back from the steering column.

Does anyone have experience with this?

 

[Guest]

Okay, I see now. Isn't the tank in bad shape already? Then what would be the harm in moving the petcock back an inch? Yes, cut the boss out and move back add some in to the front side and while you are at it, maybe lower the petcock as well to get a cavity to hold a little fuel.
Just my thought.
Laters
G

 

[Gregory]

Okay, I see now. Isn't the tank in bad shape already? Then what would be the harm in moving the petcock back an inch? Yes, cut the boss out and move back add some in to the front side and while you are at it, maybe lower the petcock as well to get a cavity to hold a little fuel.
Just my thought.
Laters
G

Thanks bud. Yep the tank needs painted anyway (inside is perfect). I wish there were a way to move the petcock without welding because I will have to pay someone more skilled than myself to do that.

 

[ozman]

i see what you mean now
why not try find a 80 model tank which has the tap further back
maybe borrow 1 to check fit

ozman

 

[tkent02]

'80 1000 tanks are like rhinocerous claws. I have been looking for four years, gave up and got a '81 750 tank for mine.

 

[Big T]

Okay, I've never done this mod, but now you understand the reason for the 1980s leverless petcock -clearance

It's pretty tight in there with the CV carb tops

You could go to a slide carb for more clearance, but that presents other problems -carb boots and throttle cables. Are you saying you have a set of 29s hanging around?

 

[ozman]

'80 1000 tanks are like rhinocerous claws. I have been looking for four years, gave up and got a '81 750 tank for mine.

so i guess that makes the 4 new tanks i have kinda rare ??


ozman

 

[Gregory]

i see what you mean now
why not try find a 80 model tank which has the tap further back
maybe borrow 1 to check fit

ozman

for my taste on this keeper project, I really am going to keep it a skunk tank somehow

 

[Gregory]

Okay, I've never done this mod, but now you understand the reason for the 1980s leverless petcock -clearance

It's pretty tight in there with the CV carb tops

You could go to a slide carb for more clearance, but that presents other problems -carb boots and throttle cables. Are you saying you have a set of 29s hanging around?

Thanks for that info, I will do some googling about leverless petcocks...that may work although I like the idea of a reserve.

yes, the 29's are slated to eventually go on my gs1000m, but had to ask if it would have worked out.

 

[Gregory]

Ok here is the progress so far. Sorry about the lousy pictures...I didn't realize my lense was sweaty.

I got all the tabs off and welded all the skunk tabs on. I was surprised how identical the frames were. Even the airbox bolts lined up properly with the tank mount.

tabs off :

Tank mount welded:

Weld seat hinges:

Weld side cover tabs:

I have everything welded and all exposed metal temporarily painted.

Here are pictures of it with all the panels bolted on. Still needs the under seat trim and gs1000 pegs shifter and brake pedal.

Then I can start thinking about what to do about the petcock.

Oh and I put gs1000 handlebars on. Everything reaches except It really needs a longer front brake hose.

 

[Gregory]

Here are some things I learned with 1100 to 1000 Body Conversion: ​

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1. Had to open up the tank mounting bracket a little to get all the wiring through to the battery compartment.​

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2. When I put the gs1000 handlebars on everything was a little tight but seems to work ok. Definitely will need a longer fron bake line though. I havent checked yet but hoping the one off of the gs1000 will suffice.​

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3. I was able to locate all the body tabs at the same spacing as was on the gs1000. I did have to redo one of the seat hinge brackets so the seat would line up right.​

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4. The Tank--- I took a members advise and opened the hole up big enough for the 1100 petcock and screen to fit in. When everything is bollted up the petcock does hit the number 1 carb. I had to cut a little bit of the lever off in order to be able to turn the lever to Prime. ​

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5. I had planned on putting gs1000 pegs on to keep the exact riding position of my gs1000 but found that the pegs have different spacing. As it turns out, I think it will be ok with the stock 1100 pegs.​

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Since the left side tank is riding on the carb, the right side edge of the tank is sitting on the rear valve cover bolt. (that makes for some vibration noises when the tank is low on fuel)​

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I still need to figure out how to either get a simple offset for the petcock or maybe a smaller petcock. I havent tried any grinding on the carb or the petcock, although it is so claose I am tempted.​

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I am going to check and see if I can fit the chrome 78 fender on it also.​

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All in all it was an easy job, probably took about 10 hours total... but now could do it much faster.​

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Next phase is to tear everything apart again and paint, polish, and tune.... but i may ride it a while first. Here are the completed pics​

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[Morrison]

I have bad vision, and your pictures gave me a headache.

 

[tkent02]

so i guess that makes the 4 new tanks i have kinda rare ??


ozman

I would have loved to find one, let alone three.

 

[Big T]

Gregory

With the petcock issue you describe, could it be you forgot the rear tank pad?

That's the one on top of the frame in front of the rear mounting bolt

 

[ozman]

Gregory

With the petcock issue you describe, could it be you forgot the rear tank pad?

That's the one on top of the frame in front of the rear mounting bolt

missing the pad and/or correct rubber and steel sleeve on rear tank mount is usually the reason for tank resting on rocker cover although might be different with 1100 engine

ozman