1983 GS 650G Full Size Caf? Project

[Mop Bucket]

1983 GS 650G Full Size Caf? Project

I love all the build treads and realized I am almost done with my project and haven?t shared the progress. This is my thanks for those that have helped me get my GS running and hopefully looking good at the end of the project.
A little back ground on me. Before buying this bike for $150 I had replaced a couple of parts on my other bike. Saw this gem and said, ?I can do that.? Learned a ton and probably still considered a newbie. I asked a few questions on the site and I was given good advice, I should sell it and get a bike in better shape. Yes, it would have been cheaper and saved a half a year of my life. But, not as fun. Also, this is my ?wife?s? bike.

The bike is a G but half the parts are off an L. I didn?t know what style I was going to do and after reading the forum for a month a restored bikes were looking good to me. But this is my ?wife?s? bike and she didn?t like the stock look. She didn?t like bobbers and when I showed her Caf? racers she said no. Found out later she didn?t like the Caf? racer I was showering her was because of the color. She actually did like the style of Caf? racers. So, that is what she picked for ?her? motorcycle. I decided not to chop anything, except the rusted out L tank I am using for the rear. This way I can do a restore if I ever got sick of Caf? style and so that I don?t get cut off from the purist help. Also figured no one would care if I chopped an L tankJ. I have it setup so later if I want to go two up all I would have to do is swap seats. Anyone have seat for sale?

The day she came home

Day one of the adventure and taking a parts inventory

Then there is a long time of no pictures but a lot of progress. During this time, I got the bike to run and replaced many many parts. Including:
L Carbs, L Oil pan, L valve cover, blinkers, front and rear breaks, front and rear master cylinders, front and rear break lines, front and rear master cylinder kits, head light bucket, head light bracket, signal flasher many electrical ends, rectifier (thanks Duaneage), rear flashers, air filter, thingy between air box and carb, ignition, helmet lock, seat lock, tach and speedo, clutch cable, speedo cable, tach cable, mirrors, L exhaust, L fender, tires, both clutch and brake levers, fork seals, and many nuts and bolts. That?s all I can think of off the top of my head. Still have a bin of L and other miscellaneous parts.

Added a few things


Clubman bars, Fork boots, L gas tank for rear end, brake light turn combo.


Mocked up before assembly and after stripping paint

Right now I am sanding the parts for paint. I am hoping to paint in a couple of days. More pictures to come on the fabrication of the seat and number placards.

Thanks and enjoy

 

[Erki]

Cool, I like the way the seats goin.

 

[Big Rich]

Ya man, cool project. Has your wife tried the bar position yet? Clubmans with stock foot controls can be a little uncomfortable for some people.

 

[Go Mifune]

That rear piece looks way too big.

 

[Mop Bucket]

That rear piece looks way too big.

My first try with fiber glass was even bigger and I wish it wasn't a failure.

Ya man, cool project. Has your wife tried the bar position yet? Clubmans with stock foot controls can be a little uncomfortable for some people.

She doesn't have her license yet, but from sitting on it she approved. I rode it for a couple hours no problem with the bars, the seat on the other hand wasn't comfortable.

Thanks for the comments

 

[Big Rich]

Glad to hear it- I tried clubmans on my stock seat and it was torture. Speaking of seats: any plans on making the foam meet up with the steel?

I like the bigger seat- I have a Hammer Endurance piece from Airtech on one of my GR's.

 

[Mop Bucket]

Glad to hear it- I tried clubmans on my stock seat and it was torture. Speaking of seats: any plans on making the foam meet up with the steel?

I like the bigger seat- I have a Hammer Endurance piece from Airtech on one of my GR's.

Yeah, the seat will gracefully curve up to the metal and be attached with snaps. The seat upholstery has got me a little worried since I am not sure how that all will work out. My mother in law said she can do upholstery so looking to see what she can do.

Here are some before pictures, well, before I stripped the paint. I was putting pieces together to get a feel for what it could look like. I did think about cutting the seat down, but didn?t think it flowed.

Mock up with paint

Tapped for cutting

From the back with new light and hole for key, since I am keeping it as close to stock as possible I planned for the lock. Also, I have easy access to tools and electrical.

 

[Mop Bucket]

To make the seat I used an L tank from a GS 650. When I lived in Vegas there was a bike wrecker that had destroyed to L's. That sucked, but it was great for me since I have a lot of the parts on my bike and spares in a bin.

After the final cut the gas hole needed to be closed. I took a piece of fiber glass and cut it to size. Using hair spray as a release I sprayed the top of my parts bin. Laid down the resin, cloth then resin again I had the perfect patch. I put the patch over the hole and laid two more layers on top of that. Sanded and no more gas hole.

Fiber glass over the hole

Sanded the ruff parts down

Picture from the front cut

Next I painted the inside now since I wouldn't be able to get to it after I weld it to the seat pan.

I then painted the seat pan for the same reason. I knew I would have to sand both on the inside but I think the rust protection worth it.

Painted seat pan attached to paint on the inside rear cover.

and the finished product

Oh yeah, first time welding. I learned how to fiber glass on my failed attempt to make the rear fairing out of fiber glass.

 

[Mop Bucket]

Since the side panels were missing I decided to add a number placard. Found one I liked on Ebay.

Wanted numbers on the placard so I had a custome paint shop create me some stinsils. But they didn't work out. Going with housing numbers instead.

fabbed up a bracket with parts available to the regular person or someone who doesn't know any better.

Mock up of bracket

With the placard attached, notice the square hole, that wasn't easy. I used a file after drilling a hole for the chrome carriage bolts I am using.

More pics to come, at my next break

 

[Guest]

Looks good. I like the way you are going with the seat. The whole bike has a nice integrated look. Will be following this build.

 

[AF_Bill]

Love the way the new seat/tail is coming out. Gives me an idea on what to do to my 650.

 

[Mop Bucket]

Love the way the new seat/tail is coming out. Gives me an idea on what to do to my 650.

Looks good. I like the way you are going with the seat. The whole bike has a nice integrated look. Will be following this build.

Thanks Bill and Bill. That is what is great about this site, we all benefit from the sharing of ideas and knowledge. I got the idea for the seat on this site. Unfortunately, I can't remember whose post I was reading to give credit. The gas tank makes the fabrication of the tail easy.

 

[Mop Bucket]

More pics on the brackets

Here is a prespective shot on the bracket

I made for template for each bracket so the holes would be consistent. I measured and marked the holes for one number plate and then photo copied it. Worked out well and did the same for other parts on the bike.

Here they are after welding and sanding. I also needed a license bracket since the old license plate bracket worked great for the light mount.

The license plate and fitting on the fender, perfect.

painted, sorry its blurry, didn't notice until now.

For my paint setup, put up plastic around walls and door. Left the door cracked for the fan and on the side I am on is the air conditioner... Painting was messier than I thought it would be. I turned the fan off since it was sending paint across the driveway. I thought I had inadvertently painted the concrete, but it was only dust, whew.

I used a couple of 2x6's, one braced across some shelves for drying and one on the garage door rails for painting. I used different hooks, but found that large loop peg board hooks worked best. I got some from Harbor Freight 1/4 inch pegs since they are the skinniest. Since the pegs don't have loops like the hooks in the picture I used duct tape. Each hook had its own length of rope. This I would hook to closet shelving hooks for easy moving. I had different hooks for the main tank, didn't want to rely on duct tape for the heavy parts.

back to the shop

 

[Mop Bucket]

For the last 48 hours I have spent 40 of them sanding, bondoing, welding, and painting. Since this was my first time doing something like this there was a lot to learn. I learned there are many ways to mess up a paint job. Like hanging hooks gauging the paint, touching the plastic of my painting area, gauging the paint with the hose while wet sanding, dust from AC unit, over painting, over sanding, masking too soon, not using mineral spirits when needed and two by fours slipping sending the gas tank to the ground.


At about hour 36 the tank slipped while I was trying to fix a problem with paper sticking to the tank. I mentioned templates before, well it back fired and bonded with the paint. The tank hit the ground, dented and then rolled into some gravel. I will have to live with the dent. I am not going through that again for awhile. I have thought about trying to make a tool to push the dent out from the inside.

Here is the process I went through to get it finished.

Bondo time, I put a lot on. I used a lot of body filler after I sanded down the globs. PO was a lot better at bondo than me and found some dents I didn?t know about. After way too much time sanding and filling I was satisfied and moved on with the paint.


Probably more bondo than needed

tail, the time pressure on the bondo makes me rush and make messes.

First I laid down the primer followed with the base coat. I painted the tank black for the faux knee dent.

I was hoping it would give it a little depth. So my inexperience showed here. I was pretty lazy with the underside of the tank and it looked better than any other painted part. In fact, it was glossy and shinny. I am guessing I over painted the other parts. I went through a ton more paint than called for in the GSR repaint tutorial. Correct me if I am wrong?


Next I taped up the knee dent. This was a noob mistake. I used photo copy paper. I also only waited 1-2 hours to tape. If I had to do it again I might have waited 48hrs or more to tape. The tape left marks. I had masking paper on hand but didn't think to use it. The paper bonded to the paint and lead up to the dent incident and messed up paint.


Taping the knee dent

All white now

More to come

 

[Mop Bucket]

1983 GS 650G Caf? Racer ?Anniversary Edition? Project

1983 GS 650G Caf? Racer ?Anniversary Edition? Project

Anyone know if I can change the thread title to 1983 GS 650G Caf? Racer ?Anniversary Edition? Project?

I used enamel paint for the base and accent color. I wanted a gold flake in a can and the only paint I could find was hobby enamel paint. Testors paint is what I used and I was thrilled with the results. I just hope it works with my other enamel paint.


Taping for the tail for accent color

After painting the stripe

Taping the side panels, there is a very fine ridge I used for the lines for the accent color.

after paint

Results with the tail

Very happy with the color and shine of the hobby paint created.

Since this is a racing bike I needed numbers.


Mocking up the back numbers

The results of 40 hours of work are better than I thought they would be, especially with all the little things that went wrong. The dent is clearly visible in this picture. The expensive clear I bought covered most blemishes. The messed up faux knee indent that I had to fix surprised me. I thought the ruff paint might make it look like a need pad or add more depth. The clear it shined right up.


Started with this

The dent really hurts me to look at. Highly recommend not dropping a tank right before clear coat time.

Not sure if I am going to follow the guide and sand and polish. I do have some bad runs in the clear. The tail piece that was almost perfect then I got my first runs when doing the clear on it, doh!

All together I am extremely happy with how the paint turned out!

 

[Mop Bucket]

Yippie

Yippie

Good bye dent! I wrapped a cloth around one of my wrenches and stuck it in the fuel gauge hole. I was able to pry out the dent!

Yippie! :dancing::dancing::dancing::dancing::dancing:

 

[Mop Bucket]

I was lucky enough to find original muffler covers at Babbits. The only problem with them is the mounting hardware is also discontinued. I fabed up some brackets. I have no idea what the original look like. Does anyone have a picture of the front mounting bracket/whatever?

Brand new, well 30 years old but in original packaging and one was open with 30 years of dust on it.

Started with my typical fabrication material

The bracket

They worked pretty good but having the original or something similar would be nice.

Final results, shiny new 30 year old muffler covers

 

[Guest]

Good effort on that tank dent! It would have been a shame to live with a dented tank after all the fine work you've done... Watching with interest...

 

[Mop Bucket]

Thanks psyguy

I finished the setup of the rear fender and hook up the light. Love the light but I am not sure it is bright enough. I know most Cafe builds go for minimal attachments and on this build I am going for functional yet 1960's racer style. I will add more reflectors as if I had purchased the bike new. I am also thinking of extra lighting. One idea is to have the whole tail section glow red when the brakes are applied. The tail is hollow and open to the air. Having a bunch of LED's up in there might be what is needed. The side of the fender as a great place to mount some lights also. Would be great visibility yet not distract from the look. Maybe some flush mount lights or something. More on that later

Here is the back view of the light, plates, reflector and fender.

The ridge where the fender is mounted to the frame is one location I was thinking of adding the flush lighting. If I can find small enough DOT lights I might do running lights, brake and turn signals.

 

[AF_Bill]

Nice paint job! I'm diggin the white (my 650 is lol). Can't wait to see it all together.