77 GS400 to Cafe Project

[ndaugbjerg]

Mark,
As much as I'd like to meet Pete and ride with him, we are probably better off with him some distance away. I have an Aussie neighbor across the street who has started brewing his own beer. A couple of months ago, he set up his bottling operation in the garage. One of the bottles blew it's cap with such force that the bottle richocheted off the front of my house. In Pete's own words," I'm sure I could find a way to lead you astray". I rest my case.
Niels

[pete]

Mark,
As much as I'd like to meet Pete and ride with him, we are probably better off with him some distance away. I have an Aussie neighbor across the street who has started brewing his own beer. A couple of months ago, he set up his bottling operation in the garage. One of the bottles blew it's cap with such force that the bottle richocheted off the front of my house. In Pete's own words," I'm sure I could find a way to lead you astray". I rest my case.
Niels

He was just giving you a free sample Niels...

[ndaugbjerg]

Mark,
You've been awfully quiet. We're expecting some mind blowing revelations soon.
Niels

[Englishman]

Mark,
You've been awfully quiet. We're expecting some mind blowing revelations soon.
Niels

Nothing blowing minds here unfortunatly

One of the issues most Cafe conversions have to solve is securly attaching the flimsly glass seat to the frame rails. In my case the seat was designed for a different bike so there are minor clearence issues to consider too. Also, I have a pet peve about conversions not looking clean under the saddle when say the bike is on the side stand and all you see is messy wiring and the scruffy underside of the glass fibre attachment. Here is my fix adapted from something I saw elsewhere -

Ground off most of the seat brackets and other metal interfearing with the seat install



Make a template that fits on the frame rails accomodating the brackets I will retain and inside the seat unit. dont worry about the square hole, its from my first attempt that failed!


Basically, Im making a flat platform that sits on the frame that the seat fits flat onto as well. Plywood would do the job, but obviously not water/weather proof. I came across a material called HDPE. A thick plastic that you can work and cut it exactly like wood, but very strong, wont rot and comes pre colored and textured. Draw back is you cant paint it or glue it. The material is used for things like cutting boards. I bought 4 black textured sheets for $40 on ebay.

Transfered the template to the HDPE sheet and using the table saw I had purchased for cutting a hardwood floor to size (I knew I would find a good use for it one day)....


A little further work with a jigsaw, a file, a knife,a drill, and....




And she fits ! Added a second piece to take the HDPE all the way to the tank (a poor joint I know) and hey presto !


This little piece will be secured to the seat unit with screws and I hope will allow the seat to be taken on/off the bike and locate and hold the front of the seat in position. The main piece will attach to the frame with clips and wont move.

Added some small strips with metal screws to hold the battery in position - I will add a strap....


I also figured the way to hold the Ducati tail light onto the tail unit. I know its looks like a black hole but the tail light is in there.....


So next up is the part Im not looking forward to, playing with glass matting and epoxy to extend the seat 4 inches and another chapter in the conversion is complete

+ this is my 100th post and I have had the bike 1 year this month. Another year and 100 posts and I may be there !

Mark

[pete]

That's great Mark! maybe not mind blowing but very productive and I must agree on your comments re: materials for the seat attachment.

I've seen a few done with wood and have always thought that's not such a grand idea... and I've seen seats attached with industrial velcro... also something that just doesn't sound like a great idea...

Nice work on that seat pan, it will definitely start coming together once you get that finished up

[Englishman]

A little off subject, but I have a new twin to ride. Picking it up Saturday






I may not be working on the 400 this week !

Mark

[7981GS]

Drool...
M/G Nakid, sweet!
Take some pic's of the ride please.

Eric

[pete]

Drool...
M/G Nakid, sweet!
Take some pic's of the ride please.

Eric

+1 on all counts! Very nice...

Years ago I wished I could get my hands on a Nevada 750, not sure why but I really liked them...

[ndaugbjerg]

Mark,
Be careful; there's a limit to how many toys a guy can have. At least, according to my ex-wife.
Niels

[Sci85]

Dang Mark, that's just not fair to those of us who want a new bike but have college bound kids!! That is such a sweet looking bike.

[Englishman]

Drool...
M/G Nakid, sweet!
Take some pic's of the ride please.

Eric

Eric and all.....
Picture Link to some more pics

Mark,
Be careful; there's a limit to how many toys a guy can have. At least, according to my ex-wife.
Niels

Niels......I think we may have the same Ex

Dang Mark, that's just not fair to those of us who want a new bike but have college bound kids!! That is such a sweet looking bike.

Its funny you should mention kids at College - This month represents my last one graduating So no sympathy here - I have paid my time (and money)...... this is my celibration.

Mark

[ndaugbjerg]

Mark,
No doubt about it; There couldn't possibly be two!
Niels

[ndaugbjerg]

Sci85,
Congratulations; I asssume they are headed south to Texas A&M! You're a lucky guy.
Niels

[pete]

C'mon Mark, no updates since May! What you been doing? Too busy riding I s'pose hey?

[Englishman]

C'mon Mark, no updates since May! What you been doing? Too busy riding I s'pose hey?

Pete, well yes I have put a few miles on the Guzzi, but I have moved a few things on with the GS. I have a small nose fairing fitted but had to modify the mounting brackets and headlight. Will take a few pics this weekend.

Mark