Motocrossx23's GS750 Cafe Build

[Motocrossx23]

Finally got around to swapping out the old crap steel phillips head screws for Z1 Enterprises SS allen bolt kit. MUCH better! Also ordered a bunch of NOS gaskets to go along with everything. Once I get my exhaust bolts out I'll be all set to paint the motor.

 

[Hoosier Daddy]

Ain't she pretty?! What did you use for the rubber cinsert sealing washers that were on the 4 outboard phillips screws on top? Not that I am pointing anything out, just curious as to what you replaced them with? I know OEM's are still available.

 

[Flyboy]

Wow, that engine looks gorgeous, watching with interest, this is going to be a looker. :dancing:

 

[Motocrossx23]

Hoosier, I haven't replaced them yet as I only swapped them temporarily until I get my gaskets in. I'll probably get some replacement ones from our machine shop at work.

Flyboy, I haven't even painted it yet lol. I'm torn between black and silver. I don't have access to an oven so I can bake on any high temp paints so I'm worried whatever I use is going to brown over time.

 

[Flyboy]

Sure you have access to an oven, we all do, just surprise the wife/GF/better half with an expenses paid trip to a spa for a week, it gives enough time for the fumes to vacate the kitchen and the rest of the house before she gets back, she will be none the wiser.

 

[Motocrossx23]

Haha, that'll put me in the dog house for sure! I'd have to split the cases in order to fit it in the oven. I'd rather not as the motor ran perfect before the tear down, I'd hate to tear the motor apart and cause headaches down the road

 

[Flyboy]

You need a new(read bigger) stove dude.

 

[Motocrossx23]

So today's task at hand is going to be getting out the 4 broken exhaust bolts and tapping the 5th one that was drilled and messed up.

 

[ScrumDown]

I'm enjoying the transformation. Keep up the good work.


(subscribed.)

 

[Motocrossx23]

Thanks! I'll have some more pictures posted later on tonight too.

 

[Guest]

I'll have some more pictures posted later on tonight too.

What a teaser !

 

[Flyboy]

yeah, where are the pics, we wanna see.......:dancing:
Psy, that avatar of yours is too creepy man, you gotta change it, it gives me the willies.

 

[Motocrossx23]

What a teaser !

Haha =P

yeah, where are the pics, we wanna see.......:dancing:
Psy, that avatar of yours is too creepy man, you gotta change it, it gives me the willies.

That's a picture of me on my old Ninja lol, I should update my signature and avatar though lol.

 

[Motocrossx23]

Oh...pictures...right!

So...I had 5 broken exhaust studs *sigh*

My first order of attack was to see if I could drill out one with left handed drill bits...no luck.

So then I decided to try to weld nuts onto the ends of the bolts...no luck. They kept on breaking off the ends and I wasted $2.00 worth of nuts (not a big deal actually lol)

Finally, I bucked up and bought a nice Titanium Nitride tap and die set from Lowes, normally I hate having to buy expensive specialty tools but this set is AWESOME!

http://www.lowes.com/ProductDisplay...gId=10051&cmRelshp=req&rel=nofollow&cId=PDIO1

So, with the help of my buddy we went to town tackling the bolts.

*Side note* It helps that I have a Titanium Carbide drill bit set...these things chewed through metal like it was playdough

Fast forward 3 hours later, a few beers and a can of PB buster...we got all of the broken exhaust bolts drilled and tapped, chased all the existing bolt holes and did some welding on the seat pan

The final results of our labor tonight:

Just a TINY bit of wiggle from the tapping, but I plan on running exhaust studs on using a TON of red Loctite.

I'm off tomorrow so my plan is to get the tail/seat pan all ready for Bondo, I'll post more pictures as I get to it tomorrow

-Chris

 

[Erki]

Looks good, I also have 4 broken exhaust bolts. Tried the welding nuts as well and ended up just welding a stud on for the remainder of the summer. May try drilling and tapping like you did after I get the engine out.

 

[Motocrossx23]

It's not too hard of a process, just take your time and make sure that you are constantly staying on track

 

[jacobdub]

Nice work! I was incredibly surprised to find no stuck nuts/bolts on mine during the whole take down. Never even had to use liquid wrench or anything. Obviously, stripped that drain plug and there were a couple missing here and there, but not too bad!

 

[Motocrossx23]

I see you're in Upstate NY? Where abouts? I'm from Buffalo actually.

 

[Hoosier Daddy]

The worst part of that whole process is getting the broken bolt drilled straight and centered. If you got 5 in a row as nice as they look in the pictures , you done good pal!
CONGRATS!

 

[Motocrossx23]

First time doing it too lol, I'm very happy with the results