1983 GS 650G Full Size Café Project

[Mop Bucket]

i would think that given the width of the rear cowl and the reg plate, that piece of plastic mudguard wouldnt improve the rain protection that much?

as for being legal, if you were to cut it right under the bottom of the reg plate would that work? it does over here where i live

The only thing is what psyguy already said and what you're looking at which is that rear guard...

I will think about it, I still have some stuff to do and the seat to finish. I remove the fender I can think of a slick way to mount the plate. Might also go for a different tail light, although the one I got I like the look.

I have been contemplating cutting the rear cover off and re-welding it to get better lines. I mocked up the pieces before I put the rubber feet on the bottom of the seat. I put them on to weld and it changed the look slightly. Also thinking about adding a Suzuki logo to the side of the tank. Something like this:



A few other things I might do is paint the head light bucket and pegs and buy another seat pan for two up riding. Quick release pegs would be nice...

[Mop Bucket]

Did some more cosmetic enhancements as I waited for carb dips to finish. Been working on the running issues and almost have them fixed. Seems to be running fine but cylinder #2 I am not sure if it is firing correctly. Added grips and new turn signals up front with pics to come.

Anyways, the speedo/tach and indicator lights had a bad paint job on them so I started sanding them down for paint. Can't decide if I will paint them white or not. I painted the head light bucket and love it. Thinking of these different combos

#1
Dummy lights white/gold strip
Tach/Speedo black

#2
Dummy lights/Tach/speedo white with gold strip over dummy lights

#3
All back except the rims around speedo/tach white

#4
All black

[spyug]

I like it just the way it is. Very nice work...well done! Now commence to cleaning up the frame and engine!

Actually ride and enjoy for now. Maybe clean it up over the winter.

Cheers,
spyug

[Mop Bucket]

I like it just the way it is. Very nice work...well done! Now commence to cleaning up the frame and engine!

Actually ride and enjoy for now. Maybe clean it up over the winter.

Cheers,
spyug

Can leave it in an OK state... so here is some of what I have been doing while waiting on the carbs and paint.

The bike after cutting the supports so the lines of the tank, seat and tail line up. Re-welding the tail to the seat burned the paint.



Chopped the fender, before



After



Painted the bucket, attempt #1



Taped the speedo and Tach for painting



Should have some more pictures later. Fabbed up another license plate holder for the cut fender and it is waiting for paint. I am still working on wiring for bonus accent brake lights and bling lights under the fenders and tank.

[Mop Bucket]

I got most of the electrical done. The rear fender has the extra brake lights and bling lights attached. Attached some more lights to the frame. I also added license plate light bolts to the number placards. The front fender was rusted out pretty bad underneath so I am still working on clean up before I can add the bling lights. Should be soon.

I also need to do one more cut on the rear fender to clean it up a little. My wife sanded down all the parts I am planning to paint so that was a big help. Hoping to paint in the morning... in 3 hours... but I am tired... and might sleep, instead...

Decided on black and white accent. If I did all white it would be too much. The accent should give it a retro feel.

[Mop Bucket]

Pictures from last night and this morning.

Paint before



After, sorry blurry



Tear down for lights and paint



Extra under tail section break lights. I am hoping it will give the back section a nice red glow when stopping at night.



This is the extra lighting that will be under each fender and the gas tank. Have the rear fender and gas tank finished. Still need a bit of cleaning to do on the front fender.



And the dirty fender before cleaning. I used a wire brush and rust remover and it is still perty bad. I will need to get the roto zip sander out for the rest. I am thinking of painting under the fender to protect from rust. Not sure if that will help anything.

[Buffalo Bill]

Circus bike?

Looking good, until those under fender circus lights showed up.

Too silly for me.

Bill

[Mop Bucket]

Here is the finished license plate bracket. The running/turn/brake light mounts to the top, then the license plate, and then I will be putting a reflector at the bottom.

[Mop Bucket]

Here are the results after cutting and reattaching the rear tail piece. I had the piece covered but the slag got under the towel. I also added some metal to the seat pan so the lines were straight and there would be something to mount the seat cover on. You can also see on the far left where the heat traveled up the mounting bracket when I welded it back to the seat. I was teetering on repainting and this pushed me over the edge.



Here is gold added to the bucket

[psyguy]

white/gold looks stunning

[Mop Bucket]

Been busy on the bike and haven't had much time to update. I am now waiting for parts to arrive as I decided to add some flare to the side of the tank.

I decided I will get rid of the faux knee pads and add real knee pads. I purchased these:



Also will be adding these to the side of the tank, but I don't like the "your Text" and had them change it to cursive Nineteen in black.

[pete]

Good idea with the knee pads! I just bought some neoprene the other day to attempt to carve my own. Will be interesting to see how they turn out compared to some off the shelf ones, but I haven't really seen any that suit the shape of the 450E/S tank all that well...

[oohsam]

Awesome job! Your'e painting is awesome. Good work.
Might need to check over that weld on the seat pan though, lots of gaps!

[Mop Bucket]

Awesome job! Your'e painting is awesome. Good work.
Might need to check over that weld on the seat pan though, lots of gaps!

Well, they are worse now.

I didn't like the lines of the tank so I chopped the braces and re-welded. Not going to post pictures welds since they are so ugly now. The welding burnt the paint and my cheap welder sent slag onto the paint. I had a towel over the paint but slag somehow rolled under it. (Caught the wife's towel on fire too but that’s another story)

So, I stripped the paint down to metal and finished the bondo Friday night. I think I mentally suppressed how much paint/prep work I would need to do cause I got sick to my stomach as the paint started bubbling.


Here is the burn marks and newly created bracket. I also added some metal to the seat pan so the seat cover will be flush with the bottom.



From the back



Doing somethings different this time. I don't like the mass produced look of the tank so I added some extra bondo.

Exhibit A



No more lip and bondo finished



Tail finished



Did some side work between fixing the carb issue, rewiring the lighting, welding again, stripping again and bondo. I entered an Unlimited Class Pinewood Derby competition.

The entry, I call it the "Silver Goose"





The paint would be better but it fell off the drying hanger. The results were better than I expected. Out the 30 entries only 8 showed up for the competition. I will post the winning race when I figure out how to get it uploaded, its too big for me to email it to myself.

[pete]

I like the bondo idea actually, definitely gives the tank that extra unique touch