GS450 Mega Build

[scottychop]

Pipes

I'm not sure what route I am going to take with the pipes yet. These stock ones are crap for sure. You looking to part ways with your Mac? I have a spare set of headers, and was thinking about making my own pipes and baffles. Check out this link for more ideas:

http://dotheton.com/index.php?topic=11248.0

[Charlie G]

Thanks for the ideas. I want to hang onto my Mac unit and try to alter to a more pleasurable tone.

cg

[scottychop]

Major Setback? You be the judge....

Finally got in the shop today. Cut and filed the spacers for between the bearings and for centering. Things looked really good until I through the front wheel on to see if things would line up ok. Then I noticed, that yes indeed, the GSXR calipers are VERY wide compared to stockers and hit the mag. That means if I want to run the stock wheels, I can't use these calipers. Or, I have to run them upside down, or reversed. Think I could space the rotors with washers?





Perhaps like this?

[scottychop]

Spacers started

Well, it turns out .25" (6.3mm) is just right for spacing out the rotors. I cut them out of Aluminum with a template, circle cutter, holesaw, jigsaw, and file. Whew! The rotors clear by a few mm's.

[gregos]

amazing job .

is this stock 16 wheel?

[pete]

Looking good Scotty... that will stop so much better than a stock 450

[scottychop]

Nope

it's a stock 19" wheel from an '80 L model. Love the avatar!

[scottychop]

Moving along....

Still working on the front brakes sadly. I've spent about 15+ hours in the shop this week fiddling around with them. I am on prototype number 3 and have hit a few sticky wickets. The first two versions didn't provide enough strength. With all of the offset problems with the rotor, I had only .125" of space on the inside to fit up a bracket. I tried beefing up a that version but it felt flimsy. I came up with another version that sits outside the stock GSXR forks, and then via spacers, goes back to the calipers.

I don't have a lathe, so I am going to have to farm these out, meaning it will be awhile before I can finally bolt these up.



And then a little inspiration for the front end. Anyone got a source for these lights??

[gregos]

looks like standart spot lights .

you can find those at any hardware store .

* although they look good , the ilumination is poor . try to find halogen lights.

[scottychop]

Yeah

that's what I thought. I just need the lenses and trim rings, as the body will need to be mounted differently. I found one source for them pretty cheaply:

3" lights

[sschering]

I don't have a lathe, so I am going to have to farm these out, meaning it will be awhile before I can finally bolt these up.

Talk to Phinney Bay Machine Works in Bremerton..

http://www.pbmwgroup.com/

The owner used to race GS's and makes quite a few custom parts for em..
He's ok with making a few one off bike parts.


Nice work.. Does the speedo drive still fit with the spacers?

[scottychop]

Sorta...

It took a bit of work to make it fit between the rotor bolts. I ended up shaving down the outside of the drive to fit.

Scott

[gregos]

which 3d software do you use?

[scottychop]

Hey,

I just use the free version of Google Sketchup. It's all I'll ever really need.

Scott

[scottychop]

Some progress...

Still working on the forks but no pictures to show. I did some work on the bike itself today. Put in a few hours working on taking out the stock gauges and putting in a mini-speedo. Not sure if I like it yet. Then I did the Coil Relay Mod. She started up fine, so I assume I did it right!