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80 GS1100E mods

  • Thread starter Thread starter Anonymous
  • Start date Start date
Ok, I got the Busa tank yesterday and today I cut the filler neck out and fit it to the GS tank. I tried butt welding some pieces of the Busa tank without much success. I kept burning through (welding is not my forte). I tried welding one on top of the other and did pretty good.

I remembered seeing a pretty cool tool in Eastwoods catalogue once upon a time. it puts a lip on sheet metal so that when you weld it together it sits flush. Here it is.
http://www.eastwood.com/shopping/pr...mID=1635&itemType=PRODUCT&RS=1&keyword=roller
The tank is thinner than the guages they list (it's like 0.025") if I remember correctly, so I hope it works.

Here is a pic of the tank with the Busa lid sitting in place. The GS tank is more rounded on top so I had to cut the Busa filler more at the front and back and then do some slight bending. All in all, it fits pretty well.

http://groups.msn.com/SuzukiGSGarage/yoshimurags1000article.msnw?action=ShowPhoto&PhotoID=4879
 
Swanny, Before long you'll have your own show on the Discovery Channel. Looks like a great project..
 
Lookin good man :)

That techy filler looks trick!

It's going to be sweet. Are you going with the brushed metal look on it then?
 
I'm not going to change the cap at all. The ring will still have the aluminum brushed look. Thanks for the compliments guys. I wasn't sure how this was going to look when I got the idea for it. The cap is bigger than the stock unit but still doesn't look out of scale.

The Busa cap is vented out of the bottom of the tank through some copper tubes, while the old GS cap is vented through the top in the cap itself. I'm planning on using the same setup as the Busa since I have the entire tank. It needs to be cut for length and installed.

I found a flange tool at Harbor Freight this morning. If they are open today, I'll pick it up. Hopefully I can get most of this done in the afternoon.

If I don't get any more ideas on this bike I can start wrapping it up. :lol:
 
tank pic

tank pic

For some reason I was not able to see the pic which is odd as i have been able to see the other pics you have posted. Did the 954 yokes work out?
 
I had to go back one pic then forward again to see it myself. Looks sharp, I like it!
 
dangit swanny, just when I think I have gotten all the parts to begin you add something else LOL

Got me an oil cooler now..

Anyways still following your progress, fixing to partake in the monoshock setup very soon..
next 2-3 wks I hope, just needing some flat stock to make the mount.

peace,
Ron
 
what make of header

what make of header

Hello Swanny
Nice bike ! Plz tell me what yr and mke is ur header and will it fit my 81 GS1100E. Keep up the nice work. Regards Archie
 
Re: what make of header

Re: what make of header

ARCHIE ANDERSON said:
Hello Swanny
Nice bike ! Plz tell me what yr and mke is ur header and will it fit my 81 GS1100E. Keep up the nice work. Regards Archie
Click to expand...
I believe it's for a '95 GSXR1100, and it's a Vance and Hines SS2R.

It is not a bolt on for the GS1100. It uses aluminum inserts at the exhaust port that are not the correct size for the GS. The flange bolt spacing is also too narrow. I had to fab parts in these areas. I still have the design files if anyone needs them.

If that isn't bad enough news for you, I'm not certain that you can use this pipe with the stock footpegs - my rearsets are 2002 1000's and are relocated to clear the pipe.
 
Busafied said:
dangit swanny, just when I think I have gotten all the parts to begin you add something else LOL

Got me an oil cooler now..

Anyways still following your progress, fixing to partake in the monoshock setup very soon..
next 2-3 wks I hope, just needing some flat stock to make the mount.

peace,
Ron
Click to expand...
Since I completed the mono-shock, I've had ideas on how to make the mount better. I think using tubular stock to hold a flat plate would look fantastic - the Ducati touch.
 
hmm got me thinking, LOL
Ok welp got home a few mins ago from out of town..
means I "might" have the time tommorrow to do some looksee'n

Will hit you up if I have any questions.
:P
 
Busafied said:
hmm got me thinking, LOL
Ok welp got home a few mins ago from out of town..
means I "might" have the time tommorrow to do some looksee'n

Will hit you up if I have any questions.
:P
Click to expand...
Keep in mind that I haven't had this bike out yet. It may be the biggest piece of garbage on 2 wheels. Another approach (less risky by far) is to do the Katman swingarm mods.

If you decide to do the mono, I'd be glad to give you any info. I've done this so many times in my head, and on the bike (trial and error) that I might be able to steer you clear of some pitfalls.
 
I was out hacking away again tonight. I fabbed a mount for the igniter and now have quite a bit of the electrical done. Need to wire the gsxr guages and headlights (which I don't have).

I also built a tool for putting a flange on the tank to mount the new gas inlet. Maybe tomorrow I'll post some pics of the tool (crude, but works) and the tank progression.

I'm thinking of possibly brazing the new opening in. Welding this thin stuff is tricky. I'd hate to burn a hole after all the work I have in it. Anyone have any opinions?
 
Swanny said:
I was out hacking away again tonight. I fabbed a mount for the igniter and now have quite a bit of the electrical done. Need to wire the gsxr guages and headlights (which I don't have).
Click to expand...
mmmmm latemodel guages..
I think I am gonna part out my '86 GSXR unsre just yet, but thinking about it..
maybe use the dual headlight setup.. maybe just stick with the big square GS headlight,, dunno too much to think about right now LOL
Gonna see how it looks with the factory guages/headlight, before I commit to wiring in some gixxer guages (but it's a nice idea) :-D

I also built a tool for putting a flange on the tank to mount the new gas inlet. Maybe tomorrow I'll post some pics of the tool (crude, but works) and the tank progression.
Click to expand...

Does this tool make the step "L" lip ?

I'm thinking of possibly brazing the new opening in. Welding this thin stuff is tricky. I'd hate to burn a hole after all the work I have in it. Anyone have any opinions?
Click to expand...

Do you have a Tig welder?
An experienced Shop, should be able to get it on for you.
I think brazing it it would NOT be a problem, but I am unsure.

Your killling me over here! :twisted: :lol: :wink:

Ok it's time (8:55am) to get up and go to the garage :lol:
 
I don't have any real progress to report. I will state it right here, if I ever find the S.O.B. that designed this wiring harness I will kill him/her slowly. I will come up with a new method to terminate their pathetic lives. A method that will surely be written about for decades after I'm gone.
 
Swanny said:
I don't have any real progress to report. I will state it right here, if I ever find the S.O.B. that designed this wiring harness I will kill him/her slowly. I will come up with a new method to terminate their pathetic lives. A method that will surely be written about for decades after I'm gone.
Click to expand...

That guy designed it with you in mind Swanny. :twisted:
 
haha felt the same way Swanny, just look at your wiring diagram, and minimize it.
I had to redo mine 3 times before I got it down to minimal wiring.
I am still not satisfied and will be redoing it again one more time.

Looking through an electrical suppliers catalog today, trying to figure out which quick connects I want to order.

Started working in the garage, but came back in after I started feeling bad..
figured I would look through my books and check the board.

Keep it up!
Ron
 
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