78 GS550 cafe project

[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

[78gscafe]

Well today was another longs day. Made up some intake manifolds to try and fit the GS750 carbs, but soon realized the actual problem. These carbs are from an 82 GS750 and I need something from a 77-79 GS750. The difference between the years is that the later carbs are butterfly and only have one throttle cable, and the early carbs are just larger versions of my existing GS550Es. I still can use the manifolds on the earlier carbs but now I need to find a set. On the positive side my Vipex shocks showed up. I bought a set of the Vipex Road Race CBF shocks. I am modifying everything as it is and I couldn't wait for the GS versions. They are amazing, and very stiff. It took awhile for them to show up, but so far they seem well worth the wait. I got more wiring done. I also finalized the mounts on the exhaust. Version eight of the gauge mount was also finished but it placed the gauges higher than expected. It makes the front end seem very tall. So I guess there is going to be a version nine. The battery strap and the rear brake reservoir were also put in. So all in all only a little closer to completion but without carbs start up is looking a lot farther off.

http://community.webshots.com/album/559109513pyYHsv

[78gscafe]

Finally got the bike running. There are a few problems, but hopefully they will all get worked out this week. I am going to have to get someone to paint the tank and tail, because the current paint is not holding up very well. I also did a rough weigh in. It came in at 440lbs wet with a full tank of gas which is a considerable drop in weight over stock without stressing the structural integrity of the frame. Ended up just trying the stock carbs to try and start it. It ran pretty well considering I did not jet the carbs (new ones are in the mail) and just adding some fuel. The brakes are amazing, and the Vipex shocks are rock solid. It feels close to a hard tail under passive riding, but as soon as I pushed they really made an impression.

http://good-times.webshots.com/album/559238695GXRHtr

[t3rmin]

Looks great!!!

[78gscafe]

Still need to finish the tail section, but it finally looks like a bike.

[Zooks]

WOW. I plan on sleeping with a picture of your bike tonight is that alright?

I love it. I want to see it complete. Finish the tail section - HURRY UP!!!

[Dignan]

How'd you get the 450 tank to sit so low on the backbone? I have the same tank.. I had to flare out the front edges to clear the frame and cave in the underside of the rear to drop down a bit on the rubber pad. Mine still sits ~1" higher than the rear section of the frame.

I dig your bike big time. Too bad (for me) that you're so quick. Mine is going to look a lot like it when I'm done..

[Ninja_Lancer]

What was involved in the GS1100 swingarm swap? Was it a bolt on?

Thanks!


N_L

[78gscafe]

Well I only flared out the front edges of the tank 1/16" on each side. What year is your bike? I didn't have to do anything else to make it fit. I did however make different stops for the front end so it wouldn't dent the tank.

The swing arm conversion is a bit dicey. The gs1100E swing arm fits perfectly between the frame, but you have to drill out the swing arm pivot holes. It involves a 16mm or 41/64" drill bit and a steady hand. I set it up on the drill press with a support under the steering head. Then clamped and the frame square to the boss. Then the part comes where you cross your fingers and go for it. You also need the swing arm pivot from the gs1100E, but it will be a bit long so you might want to turn it down or make spacers. I made spacers, but am going to turn it soon.

The tail section is in its final stages of sanding so hopefully in will be on shortly. But I did have a hiccup today, the sprocket on the transmission backed out and cut the clutch cable so 141 miles in and its back to the garage for a week.

[Dignan]

Thanks for the answer. I also have a '78 750. I haven't tried too hard to fit it yet, I think a little "coaxing" with the BFH and it'll fit like I want it to.

[78gscafe]

Well here is an updated photo. I made some Lexan panels to cover up some of the wires. They were getting a bit messy.





and here is the rest of the gallery.

http://good-times.webshots.com/album/559464885zSahZB