Frame bracing, boxing vs tubing.

[kochic]

Very slow progress on mine.
Marc
CIMG5714.jpg

[kochic]

and the shocks.
Marc
CIMG5631.jpg

[kochic]

Any update??
Here is mine,
2 degree less of rake.
Marc
CIMG6022.jpg

[GregT]

Any update??
Here is mine,
2 degree less of rake.
Marc
[ATTACH=CONFIG]62031[/ATTACH]

No crosstube in front of the motor ? Believe me, it helps.

A tip - bolt in a set of cases when you weld a crosstube in.

[kochic]

I was planning a V between exhaust 2 and 3. Is this what you are talking?
Space is really thigh with a 1 5/8 header in the way.
Marc

CIMG6033.jpg

[GregT]

I was planning a V between exhaust 2 and 3. Is this what you are talking?
Space is really thigh with a 1 5/8 header in the way.
Marc

[ATTACH=CONFIG]62036[/ATTACH]

My mistake. In the side on picture I could not see the crosstube. A vee is nice but all I did was a pair of triangular gussets below the crosstube about 50mm on a side - and with the unwelded side folded up to a 10mm lip. Made in 2mm sheet. Light and stiff.

[kochic]

My mistake. In the side on picture I could not see the crosstube. A vee is nice but all I did was a pair of triangular gussets below the crosstube about 50mm on a side - and with the unwelded side folded up to a 10mm lip. Made in 2mm sheet. Light and stiff.

Thanks, I will do this today,
Marc

[kochic]

I made these two brace.
Marc

CIMG6034.jpg

[kochic]

on the GS,
Marc
CIMG6036.jpg

[Chuck78]

Looking great Mark & Spiff!
Got any more photos or ideas on how to better brace the ignition coil & front tank mounting areas? While still being able to fit in the coils & stock tanks?
This is one big thing on my agenda for my GS400 canyon carver / track bike build, as those frames & 550's are especially very lacking in that area.

Thanks for posting up, got me excited to tackle that bike build sooner than later!
I've been sidetracked all year, end of August thru early October several twisty road GS750 trips to the mountains but more & more heavily into dirtbike woods/mountains trail riding & probably ending that by Dec 15th until mid March.

[kochic]

Thanks, I will need to buy Dyna coils to make new brackets, the weld crack on the stock coils brackets when racing.The headstock is really well braced from Suzuki on the 1000.Maybe just copy it on the 400.
Marc

[kochic]

After trying a set of Dyna coils, I just welded the underside of both stock coils brackets.Usually they crack around the spot weld.
Marc

[matt7]

on the GS,
Marc
[ATTACH=CONFIG]62043[/ATTACH]

Impressive fabrication skills Marc, this thread has made for excellent reading & viewing, thank you all!

I'm off to see if there's a full build thread for your bike!

Cheers

Matt

[metalfab]

Good job, I do have a few things to mention I do a lot of fabrication. The factory frame does have some stress because initial bending/welding during manufacturing. All the welding you have done will introduce additional stress. If you have access to getting your frame stress relieved after the fabrication is complete it will enhance the strength. It is basically placed in a kiln/oven stress in welds is released when the steel reaches 550 to 650C, and held there for one to two hours. After that the frame is totally free of oil and it is a good time to have it powder coated. If you use aluminum for engine mounts I would use 2400, or 7500 series aluminum, it is about as strong as mild steel. I like to use 6AL4V Titanium for engine mounts. This alloy is about as strong as chromoly steel, and its weight is only slightly heavier than aluminum. The 6AL4V Titanium is almost twice as strong as pure Titanium. You can buy scraps from aerospace manufacturing of 6AL4V Titanium on ebay, otherwise the price is obscene. Any bolt on structural parts you can make out of titanium will lighten and strengthen the bike. And the strange gray color of titanium looks cool, and stands out. It looks great so far, good luck with the project.

[nate665]

Hi again, been a few years since I was last on this forum, still haven't finished my gs but hoping to get there now. So tomorrow I'm starting to brace my frame.
I've been reading this; https://oldskoolsuzuki.info/archives/315
And I see it's a 60x20 1mm box steel that's recommended on the B C and E bracing, but what if I can't find that? Can i use steel tube instead? Or make a box with 1mm steel sheet?
I see both boxing and tubing being used online but I don't know about the pros and cons, I'm sure anything is better than nothing at this point but I wanna do it proper when I'm first gonna do it.

And if anyone is wondering why I'm doing this I'm fitting a sv1000 front fork and a bandit 1200 rear with öhlins shocks so I think it's for the better.

I did this bracing on mine over a decade ago, so specific memory a LITTLE fuzzy. I think B, C, and E are 1/4 plate steel. It's essentially a gusset. I also had to delete tubing A and replace with a gusset of plate to allow the tank to still mount. Test fit exhaust for F, have to make sure your header will fit.