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GSX1100EFE Rebuild

Put the pieces back on bike and took it for a test ride this morning

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Unfortunately as I was going about 80km/h down motorway the LHS mid panel flew off. I only knew because it banged my knee as it flew off. And it was not my fixing of the lugs that caused it. The top front lug which is still original wasn't seating into the rubber grommet quite right so once enough air got in behind it, it popped off. It now has a cable tie supporting it to keep it in place until i improve the connection.
I circled back round to pick it up and thankfully the panel was not damaged at all , it would seem as it banged my knee it got thrown off the road and into the grass on the side of road, thankfully I was in the slow lane at the time.
 
What I have been playing with Off & On for the last year is the spare fuel tank that i got with the package deal. It was fairly well banged up but I thought I would have a go.
Rightly or wrongly I decided to cut out the effected area, beat it into shape and get it rewelded in.

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I started off with my carpenters hammer and a sand bag which will probably make any semi decent panel beater cringe. I eventually bought a Hammer & Dolly set which made the task easier. There are multiple curves to match and it was a real pain.
I have eventually got it to this state so I need to get it welded up now. I don't know how feasible that is going to be.

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It still looks rough where I have sanded it but a bit of Bog will sought that out.
 
Nice. You've done more with two bikes in the last two years then I've done with mine in the last 20.
 
Thanks, I have also restored a 78 GS550 and 79 GS1000 prior to these 1150s. I haven't written a thread on them but might do a historical review for your entertainment.

I have taken the fairings off while I figure out how I can add in some brackets to mount the infill panel onto, so to stop it looking butt ugly I made a small fairing out of one of the broken spare fairings.
I cut it down around cracks and missing bits and came up with something similar in scale to a GS1000S fairing.
I had to cut down the clear (smokey) panel as well.

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I then painted it to match the bike colours

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I prefer its scale to the main fairing so will keep it on for a while until I sort out main fairing.
 
ensure said:
What I have been playing with Off & On for the last year is the spare fuel tank that i got with the package deal. It was fairly well banged up but I thought I would have a go.
Rightly or wrongly I decided to cut out the effected area, beat it into shape and get it rewelded in.

tank1.jpg
[/URL][/IMG]

I started off with my carpenters hammer and a sand bag which will probably make any semi decent panel beater cringe. I eventually bought a Hammer & Dolly set which made the task easier. There are multiple curves to match and it was a real pain.
I have eventually got it to this state so I need to get it welded up now. I don't know how feasible that is going to be.

20220114-161747.jpg
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20220114-161735.jpg
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It still looks rough where I have sanded it but a bit of Bog will sought that out.
Click to expand...
A lot of work I'm sure you'll get it sorted out.
 
Here is a small digression from this actual bike project.
I have been meaning to replace the fork seals on my GSX750EZ / 1100 for a while now and finally got round to it.
I replaced the LH seal as this had a tide mark around it from the oil leak. No issues doing the seal but when I went to reinstall the fork into bike it was a pain. I lined the top of tube up in triple clamp at same height as RH and tried to get axle through wheel but it wouldnt go in.

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Eventually I took it out and also removed the RH fork and replaced the seal. Before installing new fork oil I lined them up against wall and I was somewhat surprised to see this

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Different length fork tubes. The longer tube had a slightly longer upper spring in it.

I have been riding this bike for 9 years and never noticed any issue with handling over and above the basic fact that these old bikes have pretty ordinary handling at the best of times.
Seeing as I have lived with it for so long I don't see an immediate need to Fix it so I have filled them up with oil and re-installed them. I lined them up from bottom rather than top and then just pulled tube up before tightening top clamps.
 
So back to the project Bike.
I found a guy to do some welding for me on the engine casing on the lower RHS of engine case

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He made it look easy. Stuck a drill bit in the cover thread hole and welded around it, gound it down and its good as new

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Wow, nice work. The seal doesn't have to be perfect. Just trying to keep dirt out of the ignition area.
 
I don't really plan on installing the lower fairing but thought I would fix it up anyway. Like the rest of the bike it has scars on the RHS. The extent of white paint was how it came to me.
My first move was to fibreglass a ring around the hole to try and extend the curved area out to about the edge of the Contact breaker cover (the greyish area)

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To get the remainder of fairing to sit flat and an appropriate distance off the engine cover I installed the fairing on bike and then covered the engine cover in layers of newspaper and tape to make sure no resin spilled onto it.
I then taped on several layers of round cardboard and topped it off with a round metal tin lid so i had a gap of approx 15mm off the cover. More tape to hold it all in place and then I applied 2 layers of fibreglass and pressed it against the tin lid so it was nice and flat.
When it was 3/4 set I slipped a knife in between fibreglass and tin lid to separate them and then lowered the cardboard & tin lid out so the fibreglass could set without worry of it sticking to formwork.
Once it was dry I applied another couple of layers of glass and ground out the bits on the inner face that were a bit close to engine.
A bit of sanding and a coat of paint produced this result

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Good enough for me.
 
The main fairing that came with bike is a replacement type that does not include any fixings for attaching the infill panels to and looks like this

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The last major job is to add some fixings so that the black panel can be installed.
Thankfully I have the fairing from my 1100ES that I can compare to when locating fixing points.

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There is a long bracket that goes down each side that is fixed to fairing and has holes in for fixing panel to + a solid block at the bottom edge with a screw fixing

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Step 1 was to cut up some lengths of flat plastic to use as the mounts. I have used the lid off small electrical trunking.

I marked up where I wanted it to go

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I then glued it to the fairing and left it to set.

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I then fibreglassed it on properly on the underside so that infill panel will sit flat on mounting bracket. You can see a few threads of glass sticking out from underneath

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Then I had to create a mounting point for the lower connection. I made a cardbord funnell the right shape and taped it onto fairing it corerct spot (hopefully)

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I then filled it up with resin and stuffed glass fibre in there

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Once it was all set I drilled some holes to line up with infill panel.
I did a dry run install and it seemed fine

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Once I installed the fairing on the bike the panel would not quite line up properly.
Digging a bit deeper I found that the fairing bracket was slightly twisted. The one off bike (black) vs my spare one (blue) shows a moderate offset.

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I had half dropped the bike off the sidestand onto the garage wall a while back but hadn't really thought the twist was bad enough to fiddle with as I havent had the full fairing on.
Once I gave it a twist and straightened it up it all lined up Ok




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So here she is all finished

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And the big news is I sold it. I was advertising a few bits for sale and I got talking to a guy. I showed him a photo and he offered to buy it. Saves me the hassle of having to get it reregistered for the road. On the downside I now only have 5 bikes in the garage.

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Again, I'm impressed.
Regarding the fill panel, I've always thougt it would be cool to leave it completely out and paint the inside to mimic the outside. I have three of those panels, all horribly weathered. I took one and gave it a major trim... Its cool to be able to look fown and see the top of the engine again. I also like the heavily cut down fairing you showed a ways back.
 
From Dorkburger I also like the heavily cut down fairing you showed a ways back

I found a couple of other older photos with the smaller fairing on so you can get a better look

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Its now sittingon a shelf in the garage as I didn' t sell it with the bike.
 
I have one of those small fairings somewhere in my garage too.

Great fab skills, you work three times my speed.
 
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