A New Life for a 1978 GS550

[Carman34l]

I had started a thread in the Owners section with my introduction.

http://www.thegsresources.com/_forum/showthread.php?t=174110

But I would rather continue the thread here. I think it would be more appropriate as this is a ground up re-build of the bike.

This is the bike I am using as a inspiraiton:

It is the Excile Cycles Street Fighter

I found the GS550 on Craigslist, traded a TV for it. Owner claimed it has been sitting outside for over a decade, and had been a victim in a flood. And since I did not pay for the TV the bike was really FREE. Sorry, I forgot to take a before pic.

After Tearing it apart, I cut a few of the tabs off the frame that I knew would not be used again as well as the rear section of the frame.

When I picked it up the engine was seized harder than a epileptic kid playing with a laser pointer!

 

[Carman34l]

I have the engine apart and have reassembled the case to use while doing fabrication. Easier to move around that way.

I will be doing some more frame modifications, I will be lowering the seat mount bars approximately 3"-4" in the rear and 1" in the front.

I will be updating frequently, as being unemployed gives me ample time!

I plan on fabricating new intake manifolds and running two Mikuni VM 36's for carbs. I will be crafting the exhaust myself.

And I am seriously considering converting to a Center Mono-Shock rear swingarm.

Comments are Encouraged and critiques are always welcome!

 

[AF_Bill]

Looks like a good start. Exile bikes are very nice and clean. Can't wait to see it all mocked up.

 

[Detroit Diesel Man]

Not much for cutting up the classic GS look but your doing a good job so far..I love the bike your using for inspiration..that thing is cool...looks like youve got more equipment at your disposal than most people do..I'd be glad to swing down sometime in the next couple weeks(after easter) and meet you and see the progress first hand..curious about the intake system your working on as well...have never seen anything aside from 4 carb set up so am curious how thats gonna work..having a machine shop and water jet cutter would be awsome..sure would save time..I had to do all my work with just a basic lathe and by hand..lol..Looks great so far!


DDM

 

[Carman34l]

Made some more progress today.

I put together the engine case with no internals for mock-up. I am glad I held off on welding the bottom of the yamaha tank on. I would be cutting it off if I did. Did some exhaust work, and played around with some handle bar ideas. For ****s and giggles I mounted a old Auto-Meter tach I pulled out of my race car and mounted it. I looks big in the pictures but in person its not bad. I had to remove the shift light on it though as it looked hideous. I may still use the factory tach. But I would rather use a Electronic Tach than a mechanical one. I have decided against going with a mono shock swing arm. I really dont want to make this project take to long. I want it going to paint by the end of the month and on the road by Memorial Weekend. Picture time!

Side profile:

Front View:

The start of my 4 to 1 exhaust:

 

[Carman34l]

I am not going to use the Suzuki rear faring. I just had it on there for the hell of it.

I decided to not do the Mono Shock Swing Arm. Instead I am going to get a couple Burley 10.5" Shocks and move the top mount into the frame:

I took this one for my facebook buddies in Colorado:

 

[cowboyup3371]

I am officially jealous of your garage. The bike looks good and I am glad to see you are keeping the baffle in the muffler. How do you plan on joining the four pipes into the one?

 

[jyjy471]

Lookin good.I chopped a 78 550E fpr my first project and it prolly had to be the easiest work up i've done.i have some leftovers if your lookin....

 

[Carman34l]

I am officially jealous of your garage. The bike looks good and I am glad to see you are keeping the baffle in the muffler. How do you plan on joining the four pipes into the one?

I will join the left two together and the right two together making two pipes, then just above the 90 from the lower pipe join the 2 pipes.

 

[cowboyup3371]

Be interested in seeing it as I am definitely not good at welding so I have a hard time picturing it in my mind.

 

[Detroit Diesel Man]

Is that an old Yamaha RD or R5 fuel tank? Just curious..looks like it.


DDM

 

[Carman34l]

Not sure what Yamaha model it came from, but it is a Yamaha!

 

[Andr?]

Earlier XS650 1974/75 maybe. Cool looking bike you got there.

 

[Tim Tom]

Cool looking bike project! I like the bars, was that one bar that you chopped the middle out to make almost clip-ons? Are they both secure only being held in by one point? I would think if you could join them in the middle somehow you would get a better feel in the bars.

 

[Carman34l]

Cool looking bike project! I like the bars, was that one bar that you chopped the middle out to make almost clip-ons? Are they both secure only being held in by one point? I would think if you could join them in the middle somehow you would get a better feel in the bars.

Yeah, they are in there loose right now. I will be welding them to a straight pipe for the clamps. But that is the angle I want.

 

[Carman34l]

I have not really had time to do much recently. I have had to work on a few paying vehicles.

I did however pick up a new media-blast cabinet. Kind of excited about that! I just need to get a new air compressor and belt grinder and I will be in business.

Here are some recent scoot build pictures:

Started playing with how I was going to mount the rear brake

So I decided to replace the bulky factory caliper brace with a aluminum Heim jointed brace

I will be finishing the gas tank once my Acetylene and Oxygen tanks get refilled.

I cut some more of the frame, and you can see how I am going to re-work the rear of the frame by my handy cardboard crafting skills. I was a badass in kindergarden with a scissors and construction paper!

Well, moving right along! I should have all the parts ordered here in the few weeks. I am just waiting for a little more paying work to come in!

Scott

 

[dueller]

Media blast cabinet???

Media blast cabinet???

VERY envious of that. That makes cleaning things up SOOO much easier. I don't know if you have heard of using electrolysis to de-rust parts but found a link to this thread here and think I am going to be doing this to my tank as buying a replacement is not an option at the moment. On the hunt for a larger tank option. 160 miles is not really that far! Just a tip that I thought mite help. http://katriders.com/vb/showthread.php?t=95247 Wild lookin bike.

 

[Carman34l]

Very Interesting! I have been doing a lot of reading lately on Hydro-metallurgy. Specifically into removing plating without heat, and then re-plating or anodizing in a different metal.

The media-blaster will be mainly for rusted steel and corroded aluminum without removing any metal. I really hate the look of chrome and polished aluminum, so I will be anodizing or going with the brushed aluminum look.

I have been doing anodizing on a small scale for years, so thats no problem. Figuring out how to take a piece of polished aluminum and giving it a "grained" brushed aluminum look will be a learning experience. I am going to start with Stainless Steel Wool and rubbing in a straight line against the aluminum and go from there.

 

[Carman34l]

Well, I think it is about time for an update. I have not really had alot of time to work on the bike. I have spent the last couple weeks restoring a 1963 Yale forklift.

Now as far as the bike goes, I am 90% complete with the frame modifications. I relocated the upper shock mounts and fitted a new seat pan. I have the rear brake fitted.

I started looking at the engine getting a idea of what was needed for rebuilding. I noticed the valve seats and valves were in really poor shape. I was quoted a little over $100 for repairs. I found a engine from a 1981 GS550 for $50 so that is whats going in the bike. So I have a complete lower engine assembly for sale if anyone is interested.

 

[Carman34l]