The tossed 78 GS1000 rebuild thread.

[IanC]

So in response to my 'My brother killed my bike' thread. I'll post pics/progress of the rebuild here. It may not be very fast as money is tight right now but progress will keep being made.

Here's the original thread with pics of the mayhem: http://www.thegsresources.com/_forum/showthread.php?t=154988&highlight=sigh

Progress as of 3/13/10:
I'm using the accident to make her better so everything is getting stripped down to the frame and most parts will be sent to be sand blasted and powdercoated. New fender arrived today and it's in mostly ok shape, a couple very small dings and scuffs. 30 year old part so what can you expect. Forgot to get a picture of it though. Most nuts/bolts that can be will be replaced with stainless.
Tore into the dismantling. I'm kind of OCD about tearing things down so wires all get labeled and loose parts get bagged and labeled. Nothing worse then wasting a bunch of time trying to figure out what went where.

Lots of ziplock bags! Must have for any project like this.

Labeling loose parts, ignore my chicken scratch. I can at least read it. One of the nuts/bolts is wrong so I remind myself for when I make the trip to the stainless goodies store.

Wires are all labeled. Save your sanity later. Label your wires now.

Found my left rear signal bracket was bent up pretty bad. Add that to the list of things to find.

The left rear signal. DOA. Added to list.

Rear end in a state of disassemably.

Exhaust removed.

Another example of wire labeling.

Getting to the see through stage.

Rear nearly stripped.

 

[IanC]

Parts pile growing.

That's it for tonight. It'll be another week before I can do much more as I have company coming into town. Another couple good nights of work and I'll have it down to the frame.

 

[80GS1000]

Cool to see you rebuilding your bike, sorry to hear about your brother's get-off. I have a mint 80 GS1000E front end )forks, triples, wheel, no calipers) if you need all or parts.

 

[IanC]

Thanks, sourced up the forks and some wires wheels from GS1000RACER. I appreciate the help and offers everyone has given thus far and am really looking forward to getting my GS back together.

 

[knowyourenemy66]

I've got the rear turn signal and bracket when you get ready--FREE, you pay the shipping--keep posting--we like pics

 

[IanC]

Awesome! Thanks, pm sent.

 

[IanC]

Snuck into the garage for a few minutes before company came into town.


Rear of the bike pretty much stripped.

Different angle.

Entire headlight assembly is trashed. I was planning on replacing the trim ring before the accident. Glad I didn't.

My new cluster housing is scrap. Just replaced it a couple months ago.

Another couple hours when I have time and she'll be just a bare frame.

 

[IanC]

3/19/10 Update:
Frame is now nude. Called and checked around on sandblasting/powder coating today and it wasn't too bad at $300. Be sending it all off in a couple weeks.

Getting closer....

Battered front end.

Closer...

New fender vs. dead one.

Rare picture of me actually working on something. Usually I'm in the garage alone. Polishing the new fender.

Again. White Diamond polish is awesome by the way.

New fender polished and ready to put back in the box for now.

Going with the 'lay it on it's side' engine removal technique. I'm not a big guy and no way was I benching that motor outta there any other way. Stacked blocks to keep the points cover from resting on the ground, loosened everything up then unbolted it all on it's side.

Success! Engine will get a deep clean and any leaks and such fixed while it's sitting around.

Naked frame.

 

[Chris]

Well, I liked it better even when we trailered it back from NY but it'll get fixed. Nice of ya to thank the good bro who furnished turn signals. Any credit due for anyone else who furnished repair parts? Perhaps like those new forks and wheels coming your way or even the fender you're polishing? And no, you can't cannibalize my GS1000S for parts...

Dad

 

[rustybronco]

And no, you can't cannibalize my GS1000S for parts...

Dad

Now that you gone and thrown out the fact you have a Cooley, you now know we require pic's...

P.S. Welcome to the farm.

 

[Chris]

photo of my S

photo of my S

rustybronco,

If my limited command of technology permits here's a photo of the bike I'd just as soon Ian not use as a parts source...

 

[IanC]

Sorry, of course dear old dad will get accredited. Valued supplier of parts, advice and letting me know I'm an idiot when my imagination runs rampant. Definitely wouldn't think of borrowing parts from the beauty queen to fix the ugly duckling but I would like to borrow your spare seat pan to get my seat hinge brackets straightened before I take it to get powder coated. Pretty sure my seat pan is bent.

P.S. - Welcome to the forums.

 

[Chris]

Seat pan

Seat pan

Ian, I think I have a old non-stock seat which needs recovering anyway. If you can use the pan go ahead and take it. I think it was sitting over in the corner by the Gamma in the garage.

 

[IanC]

It is, I noticed it today while I was in your garage. Thanks.

 

[IanC]

Decided to give the engine a good bath today, first I had to find something to plug the exhaust ports with. Went with 1 3/4" rubber expandable freeze-out plugs.

Fit pretty nice.

All 4

Loaded up and off to the carwash

I was worried the owner might not like us using his carwash and he showed up while we were there, not only did he not mind but he brought us some other cleaner to help. Nice guy. He's some after pics. Still not spotless but the majority of the gunk is gone. I'll do some more detailed cleaning here at the house.
The oil pan was solid black and caked with gunk. Looks much better.

I'll probably take most of the engine casings and covers with me when I take the frame to the powder coaters and have them media blasted then I'll polish them all. Generator casing needs to be replaced...again. Valve cover won't come clean so may have it powder coated back to the same color.

 

[IanC]

Not a whole lot of progress while I scrounge up bits and pieces. Finding a tank is tough. Did some polishing and grabbed the spare seat pan from dad. The Good news is the seat mounts aren't bent, the bend was all in my old seat pan. I thought it was but it's still good to know for sure. Not that it would have been tough to tap them back into place but still I'd rather not have to bang on the frame. I put in my first small order with bikebandit for misc seals, gaskets, nuts and bolts and am waiting on it to come in. More orders to follow. Thus far the polishing has all been done by hand but a co worker is loaning me a bench buffer so that'll speed things up a bit.

New seat pan, at first I didn't think the seat would look that great but it's really not bad. Would need to dye it black but it'll do till I can recover some financially from the rebuild and get the custom seat I want done. Nothing is bolted up just set it all on to get an idea.

 

[Chris]

fuel tank

fuel tank

Ian,

Please take some good sharp well exposed photos of your damaged gas tank and post them or email them to me. Also, please tell me if the tank leaked after the crash.

Dad

 

[IanC]

No leaks, just that huge dent on the side. Was looking at it last night debating on trying to pop it out. I'll get some pictures of it in the sunlight when we get some more of that.
Picked up some vinyl dye from work today so I'll be dying the seat this weekend to see how it looks black.

 

[IanC]

I'm debating on blacking out the motor except the stainless hardware and all the covers. I've been finding pictures and I like it. I like it bare though too. Can't decide.

 

[Suzuki mad]

Nice job there. Pity about the alternator casing being that damaged. Am I right in thinking that the rear rails are slightly bent or is that the camera angle?