GS(X)-250E Motarding.

[mike-s]

And not so much straight as "not getting in the way"

[pete]

Even better

[mike-s]

Got the MAPP torch out, scissor jack and tied/moved everything out of the way so nothing got smoked accidentally, including removing the muffler off the header pipe.

I put the jack between the muffler mounts/pillion pegs and preloaded it so the mounts were bending out about 3-4mm.

I then applied a heap of heat to the upper and lower peices on one side until they were just starting to go cherry red


I then gave a good few twists on the scissor jack and pushed them out even further. I then let them cool down most of the way before using a little bit of sprayed water to cool it that last little bit (The last thing i need to do is muck up the makeup of the metal by annealing it).

I did this, alternating between the sides about 2 or 3 times and it worked. The last thing i need to do is file down the right mount on the inside as i don't want to move it out too much as it will make mounting the exhaust harder.


Mission accomplished.

[pete]

Nice work! Just about ready to get on with the fun stuff hey?

[mike-s]

Unfortunately i've been busy with work & so on and haven't had a chance to do much in the way of significant work on the bike. However i did squeeze in about 3-4 hours this evening.

The swingarm now isn't even remotely close to binding on the pillion peg/exhaust mounts. All i have to do now is trim the exhaust mount down on the right side to make sure i'm now not offsetting the exhaust too much with the altered mount.

Most work was done with the rear shocks tonight, i figure do as much as i can on those and then worry about going back to work on the forks and the template for the bash plate afterwards (I'm hoping to get the plate basics/bending done on Monday).

Unfortunately the bottom eyes on the new shocks are way too wide at 29mm, in order to use them on the inserts from my current shocks, and give myself sufficient thread to be comfortable with the mounting i had to cut them down width ways to 19mm as the inserts im using are 20mm. I'm still not sure how i didn't manage to make more of a mess of things by getting the cuts more inaccurate than i did (only 0.5mm off on each one, so only about 89.5', almost perfect) and cleaned them up to correct spec with a file.





For those interested the existing rubber was shot, so i used apushbike inner tube for the bottom eye rubber mounting as there's not a lot of room in there and have used fuel injection hosing cut to fit for the top eye. The fit on these are so snug i have had to use a mallet & vice to get the inner eye to fit. Unfortunately i've had to take the inserts out of the top eye so i can take those eyes down a couple of mm with a file to be narrower than the inserts (19mm).

It doesn't look much, but it took a damn long time to do with the crappy hacksaw blade i had (until my neighbour gave me a really good new one to use/keep as he doesn't use his saw anymore), and even with the new blade it still took about an hour to do all the cutting. Add to that the filing the faces of the eye smooth and there's a couple hours well spent.

[pete]

Nicely done! Hacksaws can be painfully slow on stuff like that, but if you're like me then it's a much safer option than a power saw or angle grinder with a cut off wheel.

[mike-s]

Speaking of which, my neighbour gave me his angle grinder to use, and i think I'm not going to use it and just put the hacksaw blade at an angle, bound to be safer for me than a tool I've never used before. Particularly in such a tight area.

[pete]

Definitely!

My first experience with an angle grinder was a month or so ago when the house mate asked me to give him a hand cutting one of the old drain pipes off the house just underneath the gutter.

So, two stories up on a plank on a pair of trestles with a cut off wheel on an angle grinder... got it done ok but I would've preferred a less risky introduction to a power tool like that...

[mike-s]

Would have spent more time in the garage but it was woefull weather and i just didn't want to get soaked (i end up spreading my crap out under the shelder of the garage door, not so good for diagonal rain protection).

Aside from the delay in starting i got some actual progress, finished off the second shock today and fitted them up.


Aside from the gunk i need to clean out, the chain/swingarm clearance is nearish what i was hoping for (14.5-15mm) but not quite as roomy as i wanted as it's only 11.5-12mm. I'll certainly be fabbing up a nylon rub guard for there


Not pictured is the template i worked out for the bashplate. If my plans go smoothly, 'll be taking that to the place i got it from on about Thursday so that i can get it bent up and cut to the final size i need.

[pete]

Mate, progress is good, no matter how small

Have you got plans for alternative mudguards or will you stick with the stockers?

[mike-s]

At the moment i'll be sticking with the stock ones. I might remount them so they are raised a couple of cm at some point, but we shall see.

[pete]

Cool, looking forward to seeing how this pans out

[mike-s]

Minor progress, got the bash plate cut to near final dimensions by the shop i got it from (i can do the final minor cuts & drilling myself) and dropped it off at an engineering shop to get a bend put into it. Should get it back early next week or so.

Still need to get the dremel out and take to the forks. Will try my luck and see if i can get the remenants of the existing fork seals out by cutting them. The biggest challenge is finding the time to do it all.

[pete]

I know what you mean, time is my biggest enemy too.

I need to get the forks and trees and things torqued up and get the wiring harness secured so it's safe to tow, then I need to get the new to me tail light mounting worked out, front guard straightened, and both gaurds and the tank ready for paint when I take my week off at the end of June.

It's gonna be a race because I think I'll only have one Saturday at it between now and then... I can do some at night but not the big stuff.

[mike-s]

Fark, and i thought i had a lot to do