78 GS550 cafe project

[78gscafe]

Well being new I started to post my build in the owners section and that appears to be the wrong place. I bought a 78 GS550E in January and have been making cafe modifications. So far I have a GSXR 1100 front end, GSXR wheels, GS1100E swingarm, GSXR rear sets, GS750 carbs, and a GS450E tank. Currently in the process of making my own seat and carving out the mold for my tail section that I am then going to fiberglass. Trying to keep the build updated and am posting all the pics here
http://community.webshots.com/user/...riendsfun&track_action=/MediaInfo/MediaAuthor


This is what she looked like when I first bought her.

 

[78gscafe]

Updated pictures of how the build is going.

http://community.webshots.com/user/shekawatiguy

 

[Zooks]

Looking good. Very keen to see it together.

 

[dashingemt]

tank

tank

I love the tank, how/where did you get/make it?

 

[78gscafe]

Well the tank came from a friend who was clearing out his apartment and I basically stole it. It is off of a GS450E, I think it was an 82. It doesn't look like much has happened lately but there has. The wheels were sandblasted and sent out for power coating, I picked out a semi gloss black trying to blend them into the tires. The seat has gone onto version number 3 and the rear set brackets got welded on. And a bunch of other parts showed up.


http://good-times.webshots.com/album/558571021dwbiRo

 

[LeeGS550E]

Nice work on the seat. Makes me glad to see I'm not the only one around here with a sewing machine in the house. Is that your final seat design, or are you going to keep tweaking it? And what type of foam did you use?

 

[78gscafe]

Thanks, I hope this is the last iteration of the seat. I'm only 18 and trying to save cash anywhere I can without the reducing performance or design so I used the foam from the original seat with some additional padding I found around the house.

 

[Zooks]

............with some additional padding I found around the house.

You've got the Cafe spirit right there in that sentence.

Experiment and adapt. The two greatest teachers when it comes to machinery (IMHO).

Please put the bloody thing together 8-[

I can't wait to see it.

 

[78gscafe]

Had some extra time today so I made a few fixtures to mount the seat and passenger pegs. I also cut the hoop on the back shorter for a tighter fit. Will try to get it all welded later tonight.


http://good-times.webshots.com/album/558579493OJwbYb

 

[78gscafe]

Got the tail section, passenger peg brackets, and seat mounts welded.

http://good-times.webshots.com/album/558589419NazqxF

 

[Zooks]

I was a professional welder for many years and I must say they are some of the nicest welds I've seen.

Lookin' real good buddy.

 

[LeeGS550E]

Looks like your coming along fast on this thing. It looks like you have some experience with the upholstery work. I'd suggest that when it comes time to finally put it together, heat the pleather up with a hair dryer or a wall heater. That makes it easier to stretch out. Also, if you're seams don't lay flat, you can use spray adhesive on the back side of the seam, and spread the seam flat against the surrounding fabric, sticking it flat on itself. I also found that gluing strips of foam inside of your pleats will cause them to bulge and gives it a nice "plush" look. Good work, keep it up. Heres an example of what I mean about using foam inside of the pleats.

http://i157.photobucket.com/albums/t42/zumw7332/GSAprilSeat.jpg

 

[78gscafe]

A bunch of parts showed up yesterday including the wheels back from powder coating, the front calipers, rear caliper, and the first of more than likely a few versions on the front fender.

http://good-times.webshots.com/albu...sfun&track_action=/Owner/MediaInfo/AlbumTitle

 

[78gscafe]

Spent some serious time with the grinder cleaning up the entire frame. The turn signals showed up so some brackets were made for them and the taillight. The battery box mount was also figured out. The seat was also finalized.

http://community.webshots.com/album/558693886yzVLlU

 

[78gscafe]

Started carving the foam for the tail last night.

http://community.webshots.com/album/558699102QUalVE

 

[78gscafe]

Well I have been working rather hard to try and finish the project. I can't wait to ride it. The reason for not updating is that my Photoshop won't open... so I couldn't get the photos online. However much has been done. The tail section is carved up, bought a gel battery, a chain, and a bunch of other misc parts. The frame is painted and the engine is in. I picked up a period Yoshimura R&D race exhaust and it is on. Made some headlight spacers, found out I bought the wrong rear brake and am waiting on a new one. I bought a katana brake thinking it would fit the gsxr disc, but found out they are different diameters. I started to fiberglass the tail, and yes it is my first try at this so it is pretty rough. Made a battery box and mounted it in the space below the seat. I think it looks pretty good in the sea of black. Also found out that the GS750 carbs I bought do not fit unlike what I read in the Clymer manual. So if anyone has suggestions for better performing carbs I am all ears. I was trying to make it out for the Slimey Crud Run tomorrow, but it is looking doubtful. It is all down to the details so projected fire up date is sometime next week.


Here are all the pictures
4-22-07
http://good-times.webshots.com/album/558934473fUoRIL
4-27-07
http://good-times.webshots.com/album/558934009XRhGMz
5-1-07
http://good-times.webshots.com/album/558934012fsOtsf
5-3-07
http://good-times.webshots.com/album/558934479ycDiNc
5-5-07
http://good-times.webshots.com/album/558933335adegvF

And for those of you catching up on the build here are all the build days
http://community.webshots.com/user/shekawatiguy/albums/most-recent

 

[78gscafe]

Well I couldn't get it moving this week; still working on the wiring and carb situation. But the chain is on and the tank is almost done with paint. The tail has more glass and is being sanded. The 89 GSXR 1100 rear brake showed up, but now a new brace needs to be made because the swing arm is for a top mounted brake and the GSXR is a bottom mount. I also had to make a spacer for the right rear set to clear the exhaust. Getting pretty anxious to go for a ride.


http://community.webshots.com/album/559027071QkPKIB

 

[78gscafe]

 

[oldschoolorange]

nice work man, love the choice of tank

 

[78gscafe]

Thanks, I finished painting the tank today and I also almost have the tail ready for paint. The main thing done is the pattern for the gauges. I have gone through eight different ideas. I hope this one works. The reason for so many versions is that the banjo bolt on the brake reservoir takes up a lot of space between the bars. This is the most complicated version with multiple bends and a few weld spots so it looks the most promising.


http://community.webshots.com/user/shekawatiguy/albums/most-recent