That is a thing of beauty. Nice work!
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T8erbug
Guest
Here's a nice shot of the plug coming together. I sanded and primed the 3D print with Rustoleum red v2100 primer and it bonded really well to the plastic but just didn't build high enough to fill in the imperfections quickly. I had primed and wetsanded it several times and was making slow steady progress. It was starting to smooth out nicely with just a few small low spots. I wanted to speed things up so I went and bought some Rustoleum High Build/Sandable primer and what a mistake! I sprayed on a single coat and was devastated. Even though the red primer had cured for over a 24hr period the high build stuff turned it to goo. So, I had a high build primer (that dries quickly) sitting on a semi liquid base.. As the top layer dried, the bottom layer moved and shifted with it. It ended up looking like a desert after a rain storm.. Cracks everywhere. Needless to say I'd have been better off just taking the slow and steady road haha. In the end I was able to save the 3d printed part and start from scratch with a new primer. I stayed with Rustoleum but went with a purpose built sandable primer rather than a high build/sandable primer. I finally got it close to done and started to make a new front end that will become a part of the plug out of foam and body filler (just like last time). You may wonder why I didn't just 3d print the whole thing because I have the resources and the reason is that if you look closely at any of these old fuel tanks you'll see that they are not truly symmetrical from side to side. No two tanks are exactly alike and no side is an exact mirror image of the mating side. So, I chose to sculpt and form the front end to make it look symmetrical even though it won't be rather than having a perfectly symmetrical part butt up with an imperfect one and expose the dirty details. Anyways, here's a picture of the final profile/shape of the bike at the new shop. O yeah, so in other news I finally have a dedicated workspace. No more working in a garage that's meant for cars, no more working in barns, no more moving from place to place. I finally have a spot for a while! I also picked up a 1978 GS1000E from Rexburg, ID on Sunday. It runs.. Like crap. BUT it runs! I'm stoked to start working on it when I'm done with this one.
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Did you buy that red 78 1000E with the hideous double hump seat and duck taped sissy bar? Dana coils, newer tires and electrics problem where the battery drains?
It was still listed on KSL as of last night and I half considered it but it but you're a lot closer, glad you swiped it up!
It was still listed on KSL as of last night and I half considered it but it but you're a lot closer, glad you swiped it up!
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T8erbug
Guest
HAHA yeah that's the one! It also came complete with: High CCA lawn mower battery, aftermarket square headlamp, sweet flamin' skulls double stick taped to each side of the tank, AND a beautiful rivet job on the front fender. Did I mention the custom headlamp bracketry and all the custom work it took to fit that huge arse battery in there? The previous owner gutted the interior to fit the battery and even cut the rear brake M/C out and mounted it with zip ties on the exterior... Wowsers haha. I'll definitely have to take some pictures for your enjoyment. I was able to get it for $350 though. Tough to find a runner with 1000cc's in any shape for that price! I had a fishing tournament in Burley so I figured I'd make the extra little jaunt up to Rexburg. I scored a 1.25" receiver hitch for my civic on the classifieds for $40 and made some modifications to a 2" ball hitch I got for $10 so I figured it wouldn't cost me too much extra to just haul a little trailer up there and have a look. It worked out great and the hitch even held up
Cool, more GS's is great! I finally have a garage at the house we're rehabbing & settling down in, AND an exterior basement entrance! Looking like I'll be able to become more of a GS hoarder!!! GS550 upgrades & friend's GS750C are next, then build a 325lb barebones big bore 475cc 11:1 racer out of this GS425E, & trying to pick up a beat up Rickman CR750 aftermarket CB/Z1/GS frame modded to fit a GS1100E engine already (since I can't afford a CR1000/Predator/CR-E Endurance Racer complete bike (the rare GS Rickman versions)
Your bike is looking GREAT, can't wait to see the day you get to do some mountain riding/canyon carving/track time on it! I'll have to pay you a visit next time I'm able to ride from Ohio to visit my friends in Boulder...
Your bike is looking GREAT, can't wait to see the day you get to do some mountain riding/canyon carving/track time on it! I'll have to pay you a visit next time I'm able to ride from Ohio to visit my friends in Boulder...
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T8erbug
Guest
That's awesome Chuck! I'm happy to see that I'm not the only one "hoarding" bikes haha. I have seven now and I was starting to think I was getting out of line.. buuuut as long as I compare myself to you guys I'm right on track haha. Definitely stop by if you're around! Hopefully I'll have this girl done by then so we can go hit up some canyons. There are a ton of good ones here. Salty Bike Revival did a bike show in Salt Lake City this year and it was awesome. If you get a chance to come here you oughta try and plan it around then. Tons of cool bikes
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T8erbug
Guest
Not to derail my own thread but check out the custom engineering and design work from the previous owner on my new-to-me GS1000 bahaha!
What a gem
What a gem
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Hopefully that rare Yosh pipe has not had any of that "custom" work.
That seat should be in the duct tape hall of fame.
That seat should be in the duct tape hall of fame.
Its nice once in a while to buy a bike that can simply be ridden as bought, with no need for work.....
Good God!
Good God!
Hahaha that's the one, I love it! Man who Mount their master cylinder to their plastic side cover?!
Even with all that I would've bought it and almost did like you said a 1000 is hard to find at least around our neck of the woods so I think you did OK, can't wait to see what you do with it!
Even with all that I would've bought it and almost did like you said a 1000 is hard to find at least around our neck of the woods so I think you did OK, can't wait to see what you do with it!
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scottp
Guest
Give us an update!
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T8erbug
Guest
Sorry about my disappearance! I'm back, but I've been busy with another bike of mine. My Uncle John gave me his XS400 a couple of years ago and I've just let it sit while I worked on my GS750 and other things. I saw him recently it and made me feel guilty about letting his gift sit for so long. So, I started to work on that bike. Got her running like a champ and back on the road. It actually got me all puckered up about finishing the GS750 haha. I rode the XS400 all around and loved it but there's a big difference between a small twin and an inline four. I'm excited to get the GS750 running again and while I sat and stared at it yesterday I realized a valuable lesson learned from the XS, one of the best things you can do to give a project steam is to get the engine running. It worked for the XS400 so it must work for the GS750! So that's one of my primary goals for the next week. It will run like crap with the exhaust how it is and with the crappy pod setup I bought it with but she'll run. Within two weeks I had the XS400 go from flat/bald tires, bad chain, bad fuse box, ugly wheels, etc etc to a bike that looks tons better and runs great to boot. If I can turn that one around quickly surely I can get the GS750 rideable. Anyways, here are a couple solidworks models I have done to go through the design layout of the seat, seatpan, and underpan assembly. I also modeled up my Shorai battery so I could find a home for it in there somewhere since it's the biggest item in the electrical assembly. I think I've got the rough plan laid out, now it's time to execute. Updates to follow
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T8erbug
Guest
The pipe is totally unaltered, unfortunately it will need some TLC to operate as intended.. Over the years the ride height on the GS1000 started to sag and apparently the previous owner didn't seem to mind the lack of ground clearance.. So yeah, the bottom two pipes underneath the bike are dented pretty severely
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T8erbug
Guest
Just so everybody knows, I'm wiring this dude up. I hope to have it running by the weekend... Oh while I've got your attention, where is the best place (cheapest) to purchase a FACTORY Suzuki manual for my 79' 750E? Any pointers in the right direction would be greatly appreciated. Once I wire this guy back up and get it started on the stock equipment I want to make a new wiring harness since I've eliminated so much of the stock electronics. The manual should be of great use during this time haha
Have you looked at the one on site from BassCliff.
http://zeus.mtsac.edu/~cliff/storage/gs/GS750_Service_Manual_early8valve.pdf
http://zeus.mtsac.edu/~cliff/storage/gs/GS750_Service_Manual_early8valve.pdf
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T8erbug
Guest
Thanks Steve! Got it. I search like crazy for all the info I need and get overwhelmed haha
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Peteyboy
Guest
What a cool build. Love it, keep going!
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Guest
Guest
Eastern beaver is probably a good source for the connectors you need.
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Weasel
Guest
Cool project and nice work. Man you are dedicated & patient. Coming up on 4 years, wow.
LarsKroghStea
Forum Mentor
Hi
Really love your bike! I'm working on a 1981 model gs750E my self and would like to do a similar wheel conversion. What are the dimensions on your tires and wheels?
I've also considered making my own hubs with a lathe and manual mill. There's a guy who sells bolt on conversions, but they're pretty expensive. Follow link : http://cognitomoto.com/collections/...2005-gsx-r-hub-bolt-on-conversion-laced-wheel
I'm just a bit concerned about getting the hub strong enough. If I'm using the same alloy (6061-T6 Aircraft grade aluminum) and try to follow the design closely do you think that is good enough. Or will I have to get someone to calculate material strength?
-Lars
Really love your bike! I'm working on a 1981 model gs750E my self and would like to do a similar wheel conversion. What are the dimensions on your tires and wheels?
I've also considered making my own hubs with a lathe and manual mill. There's a guy who sells bolt on conversions, but they're pretty expensive. Follow link : http://cognitomoto.com/collections/...2005-gsx-r-hub-bolt-on-conversion-laced-wheel
I'm just a bit concerned about getting the hub strong enough. If I'm using the same alloy (6061-T6 Aircraft grade aluminum) and try to follow the design closely do you think that is good enough. Or will I have to get someone to calculate material strength?
-Lars