New-2-Me '80 GS750L

[Hoosier Daddy]

Little bumpity bump bump...
I got the rear fnder mods done to relocate for a shorter "Bobbed" look and on the 3rd attempt at a seat design I am starting to like the look. Mocking them up in stryrofoam for the fibreglass buck. The first was a low squashed cafe' bum stop, the second was a street-tracker style, then this that tapers back nicely to the fender.



The bodywork is untouched yet, just on there for the seat mock-up. Thanks to kparkfan for the left side cover!! The fork gators are now ordered along with some black headlight ears and superbike bars. If they show up soon enough I could get the front end back together over the upcoming 3 day weekend, if not I'll be 'glassing a seat pan.

[Bill C.]

Great build. I will be following this to the end. Lots of great low buck ideas.

[Hoosier Daddy]

Thanks Bill C. thats how I roll, limited budget... elbow grease is cheap!

[Hoosier Daddy]

WHOO-HOO! New parts, Fed Ex man delivers in time for the 3 day weekend.

[Redneck]

Man this build looks awesome. I can't believe I have missed it up to now. I am following it now for sure. Hopefully I will get some more done today. LoL my wife saw pics of your frame and motor in your workshop and her only comment was "Look he keeps his garage clean!" Add in a dirty look. Good job bro.

Paul

[Hoosier Daddy]

...and parts are installed. Gators were advertised for a CB750 but fit the GS750 forks like a golve! I test fitted the headlight to get the look of the mounts orientaion, started out with them flipped but seem to be better this direction. Bucket is pitted so it will be coming back off but so far I am liking the look. Really liking the look and feel of the bars as well.






Hard to tell with so many colors that are not staying, red tank and white foam seat buck, but I am thinking the rear spings need to be painted black instead of silver, seem to stand out too much. Maybe once I get the seat made, the tank and side covers painted, along with my rear the wheel mounted it will tone it down... but will keep that in the back of my mind.

[chuck hahn]

I have a blue tank for that bike that is shiney as a new dime inside.. afew very minor and shallow dings with the gas cap key ..

[Hoosier Daddy]

Thanks for the offer Chuck. I'll file that away for future referance but for now I need other items. This tank turned out really nice on the inside when I used "The Works" and I plan on a custom paint job for it. Now I am saving up for carb o-rings, tires, chain, brakes, the turn sigs and tail light.

[Hoosier Daddy]

Too much time commenting on other build threads instead of updating my own... I've been playing with fiberglass again so may be the styrene is getting to me so this will be a long one to get caught up.

After I was sure I was happy with the seat shape, you have to protect the foam from the resin otherwise it melts the buck and you have to start all over. Some use packing tape or tin foil but I use a trick I found when I built R/C Boats from scratch. I mix up some 15 minute epoxy, thin it with rubbing alcohol and "paint" the styrofoam to seal it. After about 3-4 coats and you are good to go.
Then covered the frame with a large trash bag and laid a total of 6 layers of woven cloth.



After the last layer was cured I popped out the buck and rough cut off the excess with my Dremel and then sanded to the final shape using a die grinder and an 80g disc. (yes, those wheels in the background are STILL getting attention with scotchbrite)





Keep in mind I am going to cover the entire seat with black vinyl or even leather so the minor waves / imperfections aren't a big deal.

Also have sand blasted or wire wheeled more bits and painted with the VHT epoxy paint. Sprocket, air box side trim, ends of the axles and rear caliper mount along with various fasteners.



I must say I am impressed with this paint, great care was taken on the fasteners I have already installed, but it held up very well.

Last night I started something new to me. years ago I got a "Ding-King" for Christmas, you know one of those "AS SEEN ON TV!" things.



I never took much faith it how well it would perform miracles so I just threw it under my work bench for a decade. Well, this bikes tank has about 6 dents in it ranging from a half inch to the largest about 2 inches. I knew I was going to have to bondo it anyway so... what the heck.
Perforated Bovine... IT WORKS!!! Slow and steady is the case here, each time the puller pops, the dent is pulled out just a little bit more. The instructions say up to 10 pulls may be needed and that is about right. After a couple hours I have 4 of the worst dents out to where you can barely see it in the reflection and feel it... but a few more hours and the tank should be in good shape.
Today the Mailman will be bringing my carb o-rings kit I ordered from Mr. Barr and now that my paypal is back up, I am next going to order my tires-n-tubes from Motorcycle-Superstore. Next week is going to be FUN!

[Hoosier Daddy]

Hit a snag in the carb O/H. Having a spare rack I thought this would be a piece of cake. Brought home a fresh can of Berrymans and about 4 cans of carb cleaner and cleared off the engine bench.



Started out interesting with the first one being #4 so sludged up the float pivot was inside a solid mass of goo. Lots of pre-cleaning needed just to disassemble before the dip.
The flats on #1's fuel mixture screw is stripped where the PO must have had a rough time with it. No big deal I thought, I got a whole nother rack here... WRONG! Those mixture screws are ALL stripped!
So I went ahead and dissassembled the original carb to a bare body and chucked between wood blocks in the bench vise. Then soaked it with PB blaster overnight. I went out the next morning and hit just the mixture screw tower with the propane torch. I was able to get it to move about 3/4 of a turn by pushing REALLY hard with the good Snap-On screwdiver. But then it got tight agian and the screwdriver just slips. Hosed it down again and gave up for the night.
Good news is the first carb came out of the dip really nice. The spring loaded plunger in the needle valve is stuck but I have freed those up in the past by soaking in PB blaster as well.
Now how in the heck am I going to get that mixture screw out.... Hmmmmmm.

[Flyboy]

That is looking soooo nice, can't wait to see this one finished, looks like it is going to turn heads, I really like what you have done to the motor, the attention to detail shows.

[psyguy]

Now how in the heck am I going to get that mixture screw out....

carefully drill it out ?

[Hoosier Daddy]

Thanks Flyboy! Much appreciated.
and psyguy, I usually save that for the last resort when dealing with a steel screw in an aluminum hole, especially this small, and Recessed!
Tonight, I took the smallest tiny ball nose milling bit that came with my Dremel and worked it back and forth carefulley on the stripped slot. Managed to do it without hitting the side and buggering the threads and more, then heated it and got another 1/4 turn out of it.
Decided to modify an old larger shanked screwdriver on the grinder to get a narrower shaft and a sharp tip. Worked on the sripped head on the screw more with the Dremel to deepen the slot.
Then the Brother-in-law showed up to go look at a 03 Sabre for him... now his.
So I resorted to letting it soak overnight again

[psyguy]

I took the smallest tiny ball nose milling bit that came with my Dremel and worked it back and forth carefulley on the stripped slot. Managed to do it without hitting the side and buggering the threads

That would have taken some patience... largely inconcievable to me...

[Hoosier Daddy]

Success! I had to go a little deeper a couple of times and blow out the debris, then adjust the blade on my screwdriver with the bench grinder again... but once I was able to get a good bite on it, it came right out... (whew)



AND the UPS Gods smiled on me and delivered my new tires and tubes. After a lot of research I had read only one negative among numerous reviews I decided to go with Shrinko's 712's ft and rear. These are molded from Yokohama's old tooling and they are reported to be a great tire for the price



So I broke out the old trusty tire irons and got the old ones off the rims. A little more clean-up and the wheels should be ready to have the new tires mounted then clear-coated to protect them