GS1100- "Project NimRod"- Shafty

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Removed the fork tubes from the tree today. Removed the headlight, headlight mount and lower tree trim cover. Prepped and painted both levers, brake fluid resivour and triple tree clamps. I used the same black gloss engine paint with ceramic on all parts including clipons. This paint is pretty good and I'm very happy with the results. The etching primer covers very well too. I have taken apart the front foot pegs and decided to remove the rubber pads from the pegs. I wanted exposed metal pegs but haven't decided if Ill be leaving them raw or paint them. Might add some holes in the sides for something different.

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Foot pegs without rubber...don't know what I'm going to do with them

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Ill post pics tomorrow but here's what I wrenched on today.

Finish painted headlight, headlight mount, throttle housing, turn signal housing and triple tree trim cover with "suzuki" emblem removed.

Installed headlight mount and used CBR clip ons. I had to notch out a 1x1 inch in the headlight mount near the top hoop. I did this to leave some clearance for the clip on tightener bolt. OH, by the way...I flipped the headlight mount upside down to slightly lower the light and leave more than enough clearance for the clipons. All of the cafe racers I like had a lower headlight than the stock one on my bike.

I re-installed the fork tubes in the trees...about crushed 4 fingers! OUCH. I am setting the tubes approximately 1 1/2 to 2 inches above the tree.

Next on the list:

Finish installing spacers inside clip ons and find right riding angles. Install all forward controls and new black rubber and black aluminum grips.

Install headlight and birds nest of wiring inside.

Man..I wish I had a garage...doesn't seem like I got much done today but I also got my new plate, got my license and sold my tahoe. Busy.

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Finally adjusted clip ons to comfortable stance. I thought 1 1/2 inch reveil of the fork tubes above the tree was to much for me. So I brought it to 1 inch. Looks like I will have sufficient clearance for headers.

I found I had a bad clutch cable. But this is ok since I need the new one to be 8 inches shorter than stock.

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New grips.

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Riders view

[Redneck]

I will say i did like the grips.

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Made some purchases today. Looked through a salvage yard at local Yamaha dealer. Found an old 81 Honda cb 900 tank (with good petcock)...perfect for what I want to do after pounding knee dents in the sides. Also found a small Kawasaki kh 400 tank that is perfect for building my bump stop. I'm going to chop this thing up like guys did long ago. It measures between 7 and 8 inches wide which is the approximate width of the frame tail. I'm excited because I got em both for $25.

Also got a CR Competition dirt bike throttle housing to replace stock housing. I like the cleaner look this will add. I'll be wiring headlight control-starter button-on/off switch to toggle switches somewhere under the tank.

Ordered new clutch cable from an ES..It's alittle shorter than the L.

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Donor for my bump stop.

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New grips ($17) with new dirt bike throttle assembly ($13).

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Have everything together to do a di-electric rust removal in the honda tank. Using the battery charger, in the open air over a couple days. I have to wait for the rain to subside. Rust is only surface.

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Inside the tank

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More pics tomorrow...rain today.

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No problem chopping up the Kawasaki tank..just follow the dotted line.

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Finally have the whole front end together. Installed the headlight, throttle housing and grips.

As I said I ended up with Approximately 1 inch of fork tubes above the trees. Everything has turned out as I have planned. I love the look of the clip ons.