The tear down of "dorkbox"

[rustywvw]

I'm starting a build thread for my 1980 Suzuki gs550 or as I call her "dorkbox" It is now stripped to the bare frame. Time for some cleaning. 37 years of road grime and bad over spray had the frame looking pretty bad. So I'm sure the bike was dumped at one point, the current tank was red. There is a crack in the frame right where the right side exhaust mounts. It's not an important area but I will grind the crack out and weld it up. The engine might be tired. I plan to jump it with a battery and test compression. I will do a normal compression test followed by a wet test and a leak down test. The chain and cogs needed to be replaced along with the rear tire. But I ended up going through the whole bike. You guys have already been a huge help and I'm looking forward to sharing this project with you. I did a build thread on one of my VW builds years ago. I swear I spent more time typing and taking pictures than I did working on the car. So now I'm going to get to the pictures. Please feel free to comment or help out...

 

[rustywvw]

I found that one of the threaded nubs for the front fender was broken.

 

[Guest]

Always, great to see another build thread getting started. Please...oh please though, help all us out and get a free account with Flicr so you can post your pictures better. Thanks

 

[thebrandonbeezy]

Always, great to see another build thread getting started. Please...oh please though, help all us out and get a free account with Flicr so you can post your pictures better. Thanks

I second that motion, all in favor say aye.

 

[roeme]

Wohoo, build thread.

Flickr or imgur both ok. As long as it's not photobucket.

 

[thebrandonbeezy]

Whats wrong with photobucket ? Thats what i use

 

[rustywvw]

Today I took the front fork assembly apart. Now to clean parts. There is a huge swap meet in syracuse ny next weekend. I'm going to buy parts for the old lady's fatboy. I hope to find some parts for the suzuki as well. I might replace that front fork I might not. This build thread will be slow at first but I hope to keep it going through the next months. I've been toying with the idea of doing a cafe build, but I am a die hard for stock builds. Is this bike too far gone for that? Do I want to try my hand at building a custom bike? I've decided to stick with suzuki for my jap bike. I do love a KZ, but this is the same thing. I love my harleys. They are over priced under performed hunks of crap. But they sound good and ride nice (for a cowboy bike) ((oh my MC hates when I say that.)) So time to clean up and make chili.

 

[rustywvw]

Safe to say that has never been cleaned out.

 

[thebrandonbeezy]

I like the 550's my tattoo guy has one thats done up like a "rat" brat. Theyre so light and nimble feeling compaired to my 1000.

 

[roeme]

(...) I've been toying with the idea of doing a cafe build, but I am a die hard for stock builds. Is this bike too far gone for that? Do I want to try my hand at building a custom bike? (...)

Judging from the small picture I'd say your bike is near or completely stock. I'd recommend first going for stock, that way you still have the option to go caf? later on. Other way round not so much, unless you refrain form modifying the frame.

Whats wrong with photobucket ? Thats what i use

Well it's very hit-and-miss if you hail from other parts of the globe, and had some general problems during past few months. Seems to work better recently though, never had problems viewing your images.

 

[GS1150Pilot]

Cool build starting point.

 

[rustywvw]

Today I repaired the crack and welded the rear peg mount back on. I cleaned the grease and grime off the frame and started to remove the over spray. It looks like the frame has been painted before. But not good painted. They probably painted the bike with the engine in it...

 

[rustywvw]

I'm going to try something.....

This is a few pictures of the frame in its current state.

 

[rustywvw]

After some longs hours at work, I have placed my first order of parts for dorkbox. Chain kit, brake pad sets and a rear tire. I still need a lot of parts for the old girl, and drunk Andy strikes again..... I ruined the lower head bearing when I removed it from the stem. I did however find a set of side covers at the super swap. Also bought a full set of tins for my harley. bye bye money...... Today I called in sick to work, after I snowblow the drive I think I'll clean up the frame and get it ready for paint.

 

[rustywvw]

Today was "nice" out. So I took advantage and sand blasted those hard to reach spots on the frame. My head bearings came in the mail and the triple tree has been painted. I still Need to go see the guy in marion for parts. Once I figure out the website I will add a link in my thingy. As for the cafe build.... I've decided to keep it stock. I don't know if it will sell this spring but if it doesn't I will put it on the road and rock it out. I will be back tomorrow with more pictures of the slow progress.

 

[Sam 78 GS750]

Today I repaired the crack and welded the rear peg mount back on. I cleaned the grease and grime off the frame and started to remove the over spray. It looks like the frame has been painted before. But not good painted. They probably painted the bike with the engine in it...
View attachment 49727

Is that a crack in the frame in this pic?

 

[rustywvw]

Is that a crack in the frame in this pic?

Yes. It must have cracked when it was dumped by a previous owner. It wasn't in and area that would affect the bike at all.