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Hillsy's GS 450 cafe build

BentRod said:
I've been watching, and I'm very impressed. Wish I could pull off this kind of project.
The bike looks like its going to be a lot of fun.

can you give us any clues on what we can anticipate? any design ideas floating around?


couple things I am curious about:
1) that rear brake. is that really where it is going to stay? can you bleed it in that position?

2) rear shocks....those are definately originals... are they any good still?
Click to expand...

Design ideas? It's going to be an old-school cafe style, with slightly more modern running gear. I'm thinking of a colored frame (maybe burnt orange?), silver engine with polished cases, and possibly silver tank, seat, guards

As for the rear brake, I will have to unbolt the caliper (from the disc) and hold it upright to bleed it. No biggie :D

The rear shocks are pretty shot - and they're a bit short anyway. I'll be looking for replacements.

Cheers....hillsy
 
salty_monk said:
Wouldn't it have been easier to turn the wheel around & run it "backwards". Looks like you could have even reversed the disk too as it's a flat one...

Dan :)
Click to expand...


I wouldn't have been able to use the FZR caliper if I ran it on the other side (it's RHS).
Also, I wasn't too keen on reversing the rim (the spokes aren't symmetrical). I wasn't sure if this would comprimise the integrity of the wheel :confused:

And finally, it wouldn't match the rear. It's all about style, after all...:p
 
gs400s

gs400s

Hi ! I look at your project gs450 and I have some questions . I got a frame from canadian model same as your : a gs400s '84 ( except here in cdn we get the 8 valves 400cc the u.s. don't get ) . Since I kept only the frame from this old Gs ( parting all the rest including fork & triple clamp ) I purchase a gs500 for near nothing . The 500 motor will fit bolt on style ( except for the exhaust manifold ) . But the forks ( more precisely the steerer tube ) won't . The steerer from the gs500 is too short . So i'm looking for another donor fork . Your is from which Fzr ???( 250 hre in cdn are non existent or only avalaible on grey market ) . Thanks
 
Wow - finally got to work on this again.....

Got the rearsets and rear brake sorted:
IMG_3683.jpg

IMG_3685.jpg


And a side shot with the mufflers
IMG_3688.jpg


The mufflers are not sitting as "upswept" as I would have liked, but the rearset position dictated where they had to go :mad:

Next up is mounting the tank and seat.......maybe don't hold your breath on these considering my track record :rolleyes:
 
Hi Hillsy, love the lines you have created with the clip-ons, 650 tank and 900SS seat-ducktail shell. The pipes being flatter than other Cafes will give yours an older style look, no problem with that really. Catch ya later, cheers.
 
Hillsy,

Love those low and straight pipes. Also love the loop at the rear of the frame. I don't know why everyone who does a cafe build doesn't do that.

Keep up the good work!
 
So I had to move the fuel tap forward to clear the frame (GS650 tank on GS450 frame is not a perfect fit .....)

So I pulled out the big old soldering iron that I inherited from my dad:
IMG_3771.jpg

To get some perspective of the size of the thing, that's the fuel tap near the bottom of the pic :eek:


And it's got a great name.....
IMG_3770.jpg



So anyway, I didn't get any before pics (sorry :( ), but here's the end result:
IMG_3768.jpg

I basically made up a new mounting plate (with nuts welded in) and a cover for the old tap hole. I cut a new hole for the re-postioned mounting plate and soldered both of them in. I'd considered getting out the propane torch, but I was a bit wary that the tank still had some fumes in there, so the soldering iron did the trick safely ;)

And the tap just clears the carbs now (but clear is clear :clap:):
IMG_3772.jpg


I've started making a "frame" to mount the seat unit to (and then mount to the frame), but it turned out a bit....awkward..... so I'm considering mounting the seat unit with some hinges and some sort of clasp (I want easy access to the underseat electrical area). Hmmm - going to think a bit more about that one :rolleyes:
 
Do the lights dim all over town when you fire that soldering iron up?:eek:
That thing is AWESOME!
 
I'm liking this! Great line with the 650 tank (a natural) and that seat.
I'll keep checkin'
 
How did I miss this build. Your bike looks sweet. Keep it up.

Charlie G
 
I love it! Can't wait to see how your project is progressing! Waiting for more pictures is torture :)
 
Come on Hillsy, 'fess up, time for an update!

The way mine's going it's possible I'll be on two wheels by maybe March next year... would be good to be able to get a pair of unique 450's out for a ride!
 
pete said:
Come on Hillsy, 'fess up, time for an update!

The way mine's going it's possible I'll be on two wheels by maybe March next year... would be good to be able to get a pair of unique 450's out for a ride!
Click to expand...

Well, it's all in many bits at the moment (has been for some time actually :().

I've welded a plate in under the rear hoop to house all the electrics and stuff, and I'm working out a neater way of mounting the seat unit, but things have been slow in the garage with other stuff going on (work, kids, blah blah).

Hopefully I will get some time to work on it some more after Xmas and post some more pics - but I did say from the start it was going to be a SLOW project :-\\\
 
Haha I understand... completely. Mine'll be 9 years since I rode it next year, and 5 years since I started dismantling... now that's what I call slow!

Sound like you've at least got a little done which is always a good start.

I'm finally getting along with mine, although hitting a little wall with the valves at the moment.
 
Looking good Hillsy,
I only just found this thread.
Question:
What wire did you use to "solder" the plate in for the fuel tap?
Look forward to some more pics.
Cheers.
 
landshark said:
Looking good Hillsy,
I only just found this thread.
Question:
What wire did you use to "solder" the plate in for the fuel tap?
Look forward to some more pics.
Cheers.
Click to expand...

I have no idea what type it is - it was left over with the soldering iron I inherited from my dad (I remember as a kid watching him use it to solder in a new base in our home's hot water system header tank. To this day I still think that was a pretty amazing thing to watch someone do).

Anyways, it's pretty thick soldering wire - about 3mm - and it has no flux in it (I also inherited an old tin of flux).
 
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