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GS1100G Cafe Racer

  • Thread starter Thread starter oohsam
  • Start date Start date
Thanks Flyboy.

Oh I forgot all about the Torque Arm! Ill get onto that.
I could chase the threads with a tab, but the rear swingarb bolts are HUGE. I dont have a tap anywhere near that size....
I think I'll just screw in the bolts for the rear swingarm...The engine bolts will be a bit tricky to leave in there though, as they are quite long...

I have to have my compliance plate on the bike, its legally required, but I'll pull it off tonight and rivet it back on when its back :)
 
Not only the torque arm, but the hole where the actual shaft for the rear brake pedal goes through.
You may just want to pop down to your local supply store and pick up some short bolts with the same thread as your engine bolts to screw in there, can't cost more than a buck or two, surely.
Yeah the swing arm slugs on the shafties are huge, I would have probably left mine in, but I am too paranoid about them going missing at the powder coaters, but that is just me, maybe leave them in and let the guy know, they better still be there under threat of mutilation and death if they are not.;)

that is why I went with 2K instead of powder in the end, much less fuss, and it cures just as hard, also easier to touch up and maintain, if you do get a scratch on it, powder tends to chip off in pieces.
And the 2K shines just as goos as powder, check my rebuild thread and see how my frame came out, I am quite happy.
 
Ah ok,
With the brake pedal, I'm not actually using it, that entire part has been cut off the frame. I've replaced the rear sets with GSXR rearsets and removed any piece that is not required...

Hmm now u got me thinking if I should go 2Pak.....
Damn you flyboy!
 
For what it's worth, powder would have worked out cheaper for me, all the time and materials to strip the frame, then the cost of the paint, it added up to more than powder would have cost me.
But i am glad I went that route.
 
Hey just a word of caution on those mini switches, they look good and do the job but the chrome tops rust in no time... A friend of mine has them on his bike.
 
I like powdercoated frame as due to its thickness compared to the paint, it gives the frame a more solid appearance.
 
Thanks psyguy. I think I will be painting these covers in....Chrome paint..hehe so they dont rust ;)

Yeah im going back and forth atm with powdercoat or 2K....
 
Wow you've been shopping! Haha

What size headlight is that? 7 inch? If so, where'd you get it? And is it a standard H4 bulb?

I'm liking what you're doing :D
 
Looks like a fun project. Looking forward to watching the progress...
 
Hey Pete,
I've been buying all the parts I need over the last 6 months. Its taken me 6 months to ge the bike to this point. I watch alot of OCC, and I find that they do their first 'mock build' to make sure everything fits, then break it all down, paint and re-assemble.
I seen alot of builds where they strip down the bike, get the frame painted and then find some road blocks..

I wanted to make sure I did all the welding and cutting and was happy with the look of the bike before I broke it down.
Im glad I did, as I changed alot of things that I was not happy with...Rearsets are a prime example. I'll post some pics later of what had before to show you terrible they looked.

The headlight is a 7 inch. Took me a while to find exactly what I wanted. I got it from modern motorcycle company here in Melbourne. They do alot of cafe builds and have a great little shop. Very nice guys. They sell alot of stuff...

http://www.modernmotorcyclecompany.com/

If you want one I am happy to pick one up and send it your way.
It does have a H4 bulb (high and low beam).
 
I watch alot of OCC, and I find that they do their first 'mock build' to make sure everything fits, then break it all down, paint and re-assemble.
Click to expand...

So those idjits were good for something afterall. Actually, they got me started on bike customizing myself. I watched them from the first show and figured if twits like that could do it then so could I. I was halfways right. It took me 2 or 3 bikes to get the hang of it but by the time I got to doing my XS650 Tracker I had it down. I still took me about 10 times longer than the OCC boys to complete it. Mind you I don't have a million dollar shop with milling machines and "flowjets" and 5 axis CNC machines either. I can't believe they are still on TV either since the chopper and custom bike craze seems to have tanked with the economy. The workmanship isn't all that great either from some of the bikes I've seen up close and I've heard some bad things about their business practices too. Well they've made their millions and I haven't so I guess they are a success.

Good work on the project. Who says you don't do a professional job. Looks damn good to me, I'll be following along too.

Cheers,
Spyug
 
Ok, so the bike is all broken down now and ready to send off to the powder coaters (might drop it off tomorrow)
After much thought and research, I did decide to go for powdercoat. It just seems right in my head.

In Australia, it is a legal requirement to have a rear fender on the bike. I really dont want on there but I'll need it if I want to get the bike registered. Then I can remove it later ;)

Since I cut the frame, there was nowhere for the rear fender to mount to, so I welded some tabs on the back of the frame about 10 mins ago. Came out good.

I also closed the sides of the electrics box which the cafe racer seat will cover...
I cut off all the tabs I didnt need. Including the where the old brake pedal and master cylinder went, and the mounts for it, the mounts for the airbox, and all the cable holder things. Basically just cleaned up the frame. Makes a big difference. I'm really going for that sleek look.

Enough talking. Pic time...

165.JPG


166.JPG


168.JPG


The polished bits..as promised.

169.JPG


172.JPG



You spotted correctly...The PO really banged this up..Not sure what to do..Might just have to use it.

171.JPG



Atleast this one was ok..

173.JPG
 
spyug said:
So those idjits were good for something afterall. Actually, they got me started on bike customizing myself. I watched them from the first show and figured if twits like that could do it then so could I. I was halfways right. It took me 2 or 3 bikes to get the hang of it but by the time I got to doing my XS650 Tracker I had it down. I still took me about 10 times longer than the OCC boys to complete it. Mind you I don't have a million dollar shop with milling machines and "flowjets" and 5 axis CNC machines either. I can't believe they are still on TV either since the chopper and custom bike craze seems to have tanked with the economy. The workmanship isn't all that great either from some of the bikes I've seen up close and I've heard some bad things about their business practices too. Well they've made their millions and I haven't so I guess they are a success.

Good work on the project. Who says you don't do a professional job. Looks damn good to me, I'll be following along too.

Cheers,
Spyug
Click to expand...

Thats Spyug!
Its nice to see people appreciate my work.
I think I'm doing an Ok job, but I think there are so many parts of my work that require a little more finesse. My finishing is just not that great. If you look up close to my welds, you'll see that they are not that neat. The thing that sux, is that my last welds (on the tabs for the rear fender) look like someone else did them. They are unreal. I finally go the hang of welding...but I have no more welding to do ! ha!!

Yeah I really like OCC as I find that my learning style is a mimic style. if I see someone doing something, i am able to mimic it almost 100% (except welding!)
I hate the politics and life drama of the show...that and Biker Build off, great shows I must say..

If I was to do this build again I'd do things quite differently now that I have the experience. I think my next build wil be alot better (better not let the wife hear me say "NEXT BUILD"....

;)
 
I finally go the hang of welding...but I have no more welding to do ! ha!!
Click to expand...
Your doing alright, if you are getting some good results you could grind and go back over the rearset mounts. I'm am not being critical but if YOU want it would be a lot easier to clean up the welds before powder coat.
 
+1 on the work, I like it, and I think you are doing just fine, following along with great interest, keep it up.

Its just a sticker, rip it off and replace it, they are freely available on fleabay or where ever you get your suzuki parts from, they not outrageously expensive either.

171.JPG
 
Mate that's some good progress and nice work on the polishing!

+1 on what Flyboy said, just get a new one or two. Mine seemed to have survived ok and I paint stripped the black off so they have the same polished look as yours.

Cheers for the tip on the headlight, I'll have a look at their site and see what they have to offer.

As to the rear gaurd, yeah, gotta do it for the safety cert... at least with my 450 I need the gaurd for the "look" of the scrambler, so that works well for me anyways :)
 
I called up peter stevens (bike shop) they had the emblem covers in stock with suzuki, so I ordered some :)
Had no idea they come right off...

also, just sent my rear wheel for powdercoat, and my worst fears..
My spline is gone beyond belif!
Back to ebay I go. lol.

spline.JPG
 
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