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GS450 Mega Build

  • Thread starter Thread starter scottychop
  • Start date Start date
S

scottychop

Guest
This thread will be a culmination in 15 years riding, wrenching, chopping, and hopping up motorcycles older than 1981. I hope to start a mega project that I am reluctant to call cafe, street fighter, or GSXR conversion because it will be all of those things and much more. I aim to fab everything I can one the bike on slow bit at a time.

Page 1-6 GSXR Front Forks.
Page 7 - Under seat Electric panel - Link
Page 8-13 - Rear End? - Link
Page 18 - DIY Earle's SS brake lines - link
Page 19 - Finished! - link

Without further ado.....drilling rotors:
Increased surface area for cooling by double.

Rotor1.jpg


Rotor2.jpg


Rotor3.jpg


Rotor4.jpg


Rotor5.jpg


Rotor6.jpg
 
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This is going to be good!

I like the black and white photos very artsy fartsy. An interesting precursor of how this build might go.

Good job on the drilling. Tedious ain't it. Once you get the first one done the next ones follow quite easily I find, however. Did you find the cutting easy? Some disks are hard to cut and yet others cut like butter. I used to use drill bits but on the advice of guys from the XS650 forum I changed to end mills and they seem to do a quicker job.

Whats next on the agenda?

Looking forward to seeing your next part of the puzzle.

Good luck with it.

Spyug
 
Great job on the drilling and the photography! This build should be very interesting!:cool:
 
Thanks

Thanks

The drilling went pretty smoothly. I expected it to be much harder based on posts from others. I used new, cobalt bits and a lot of oil (canola!). The shop smelled great. :lol:

Oh, and if anyone wants a template made up, I can whip these out quick in Google Sketchup. Here is a tutuorial for those who don't know how to make something like this:

http://www.youtube.com/watch?v=KMK3BXeC28Y

Can we embed youtube here?
 
I'm along for the ride on this one, very keen to see what you can with a 450 :cool:
 
O_o

O_o

Are you doing this on the black GS450 you rode here? Or is this another GS450?

It's looking good already. Drilled rotors... Looks cool and better performance. It's a win-win situation! I'm thinking I should do that too when school starts. I'm definitely subscribing to this :D Oh yeah, my roadtrip is ending way too early so I'll be home tomorrow. Back to work on my GS450 hehe...
 
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Progress.....

Progress.....

Drilled the other rotor today....Yes I am going with dual front disks. The first major change I wanted to make to the bike was in suspension. I acquired a nice looking 1993 GSXR front end and have been slowly, painstakingly, measuring to make it fit. The triple trees are a match, so no changes there. The wheel bearings were a bit harder due to the odd sizes, and the fact that I wanted to keep my wheels for now. VXB bearings supplied the new ones. Then I ordered some shim stock and spacers for the front axle. Here is what I have come up with so far for fabrication:

DSC_5277.jpg


DSC_5275.jpg


AxleSpacers.jpg
 
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Subscribed! Busting out the popcorn! This looks like its gonna be sweet build. I love the black and white photos, and the 3D modeling is great to see. Keep us updated.
 
Nice, nice and NICE !!

Uhmmm, you've done this before.....great drawings.

Subscribed.:)
 
Your B&W photos are amazing.
I had no idea you could order metal stock online.
The things you learn here.
 
Subscribing!

Looks like you're doing a good job with planning! I can't wait to see how this turns out.

What other ideas do you have coming up for us?
 
Ha!

Ha!

Give away all my surprises? Secrets... all of them! Actually, I am not quite sure yet. I have a number of ideas and parts that I may use, and am letting the bike dictate where it wants to go. Cost, is another factor.:D
 
That thing is sweet... an awesome job that would translate extremely well to the 450 :D

I may have to steal 2 of his ideas... the rear hugger (nice and subtle but very very useful) and the embedded LED brake light in the tail with the small clear lense indicators.
 
New Calipers

New Calipers

arrived today. Not to modern, but better than those single pot stockers! Too all you techies, will I need to run the GSXR master cylinder or do you think I'll do ok with the stock lever displacement?

P1000901.jpg
 
Every GSXR Master I have seen is 5/8" bore. Single disc Suzuki is 14mm bore. If you want to stay more old skool you should be able to run a twin disc suzuki master or a Kawasaki Ninja master (late 80's model).

Sure there are plenty others with a 5/8" bore. You could try the stock one but you may find the lever pulls back to the bars before the brakes bite....

Dan :)
 
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