Seven loose fillings - what? wow

[JanMedSlangen]

Hello from sweden!
This is/was a Suzuki GS 500(as sold in Sweden) E from 78 with the name "Seven loose fillings", named by previous owner who was a dentist. He bought the bike new in 78 and started his build in 81 i think. I have most of the papers on the build with the earliest from 82. He was a friend of my father but passed away 10 years ago. In 2013 i bought the bike from his widow. Got it running, drove it a while and then started making it better.
This bike features
- Performance-modded head made in 82
- Overbore kit, don't know what and from where, ideas? My father think it was 605 or 610cc
- Kalgaard inside and out
- Custom made fairings x 2
- ?hlins shocks
- Prepped fork
- Metmachex swingarm
- It had a different ignition system but it broke down so i put the original back in
- Oil cooler, not mounted
- and so on.

After i got it running i drove it for a while before i started making my own things for it. I was 17 when i started and progress have been slow due to breakdowns(all electrical), studies, lack of money and so on. Some of the things i've got.
- 100% custom made seat in fibreglass/carbon (Only a prototype mounted in the pictures, the new one is on the floor)
- Pegs made by me
- Acewell speedo
- Switched the clipons for a handlebar since it was almost impossible to drive with the pegs up my ass.
- Modern rectifier/regulator
- A couple of dynoruns
- And some other things.

Coming this spring:
- Finishing and mounting the seat.
- Paint?
- Sorting the wires, mounted for testing right now
- Reweld some bird**** made by previous owner, relocate pegs.

Future:
- Bigger carbs, it needs it.
- Slimmed wires and electronics
- Finally getting to ride it for real

I'll post some pictures for you. The black fairings weighs around 30kg in total and made driving horrible.

 

[JanMedSlangen]

https://www.youtube.com/watch?v=WmGF8XcZ11E

https://www.youtube.com/watch?v=3bBXatFtRmA

 

[850 Combat]

Gee Whiz. I like that a whole lot! Good looking and home designed and built, it appears.

 

[bobgroger]

Nice job. An improvement IMO....

 

[steve murdoch]

Welcome to the site, Jan.
While i like the look of the old single seat, tail piece/side cover combo, your new home made seat will offer better ergos.
The Dunstall pipe has a nice sound.

 

[roeme]

Welcome.

What air filters are you using?

 

[GS1150Pilot]

What a gorgeous machine!

 

[dorkburger]

Welcome. Definitely some impressive 'glass work. Nice job.

 

[JanMedSlangen]

Thanks for the support, i guess i've come to the right place. The seat was a true pain, aprox 200-300 hours from CAD to first finished seat but thats what it takes when you don't find what you like on ebay and doing it the way i did with a reusable mold. I'd love to have some sidecovers but it is just to much work to do from scratch right now but since i don't plan on selling the beast but use it as a learning-platform nothing is impossible.

I don't know what make the pods are. I've done a couple of stacks in carbon and i'm thinking about mounting them with a larger filter covering all 4 carbs(picture). But the carb-issue isn't solved yet.

Other tricky bits:
Arm for shifter and brake in carbon tubes with glued aluminium inserts that is adjustable by turning(one end is left-thread)

Bought another one like this the other weekend. Worst bike i've laid my eyes on. Only for parts. Thank god it was cheap

I'll try to update as it progresses.

 

[850 Combat]

So those molds are CAD and CNC?

 

[JanMedSlangen]

So those molds are CAD and CNC?

Yep! Milled from styrofoam with a 5-axis wooden mill. Made at my university. Should have done them in MDF instead but this was cheaper and quicker in the mill. Some may call it cheating but it's atleast more built than bought.

 

[850 Combat]

It would only be cheating if you digitized someone else's with a lazer, and made that. I've just never heard of anyone doing it. That's awesome.

 

[JanMedSlangen]

It would only be cheating if you digitized someone else's with a lazer, and made that. I've just never heard of anyone doing it. That's awesome.

Thanks! I've had some experience with it from things like these: http://www.liuformulastudent.se/

 

[JanMedSlangen]

Got the bike back and borrowed a friends welder, got rid of the old pegmounts and welded some new one in.

 

[JanMedSlangen]

 

[JTGS850GL]

Liked it batter with the black faring only without the tank cover.

 

[JanMedSlangen]

Liked it batter with the black faring only without the tank cover.

The problem is that the black stuff is gigantic and completely dwarfs the tank without the tank cover. Problem 2 is that with all the black fairings on you have to be a gymnast to ride it.

 

[JanMedSlangen]

Back to university and Link?ping, went home over christmas and stripped the bike and got the frame down to Link?ping, we have a workshop at campus that i thought i should get some use of.

I didnt like the pegmounts i did earlier so i cut them off and made new ones. Made out of 60x60mm squaretubing with M8 weldnuts(?). Tried to do the notches by hand but switched to our mill. Turned ut much better. I'm really no good at welding but i got the left one okay so i'll show you that. TIG-welded.

 

[JanMedSlangen]

Next on the list was a silencer mount. Found the one made by the previous owner in the car, it had fallen of due to poor weld and vibration. The new one needed to be rubbermounted so i took some 40x40, notched and drilled in the mill and turned some aluminium bushes to save the rubber from being squeezed to death.

 

[JanMedSlangen]

Almost every hole was filled with bodyfiller. Drilled it out, cleaned it up and welded a plate over