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Well, I guess this bike is going to turn into a little bit of a project. The basics: 1978 GS1000E, 6200 original miles. Completely original except for a Kerker 4 into 1, and a set of pods. A one owner bike for 30 years (1800 miles), and the second owner bought it, installed the pods and exhaust, and rode it hard, put it away wet. It runs "ok" as-is. I paid 700.00 for it. The tires (original?) are hard as a rock, original chain, basically a great bike to play with.
OFD stands for Obsessive Fabrication Disorder. I like to make stuff, and the first step is going to be making an airbox and air filter housing assembly out of aluminum. I bought an airbox, thinking the air filter was in it (like my G). Finding out that the filter was seperate, I advertised for one and hunted around on ebay - no luck. 7981GS offered one as a template so I could make one, but Rustybronco is local to me and was cool enough to offer his for me to reverse engineer. I decided to make a new airbox out of aluminum too, so it would be easier to install and remove. This is what I came up with:
These are the three views. I tried to get the interior volumes of these boxes to match the originals as close as possible, so the air management would be close to stock. I can't see how a set of pods would improve the flow much over this system. Here is a better side view:
The stock air filter box had roughly 6 1/2 square inches of opening for air inlet into the box, so I will add (22) 5/8" diameter holes to replicate that. After designing the filter housing, I did a quick cardboard mock-up to make sure it would actually fit:
I will make better posterboard mock-ups before I start butchering up the aluminum.
The overall plan for the bike is to improve the suspension and make it a little better handling than stock. I am considering making an aluminum swingarm, and swapping on an inverted front end. Maybe some Works shocks, a different seat, etc. I am suspecting that the twisted "highway bars" were installed too tight and may have dimpled the frame, so I'm not too worried about destroying a museum piece. Overall the bike is in decent condition, and will be perfect for this project.
Once again - big thanks to Dale for trusting me and loaning out his air filter box. As fast as this bike is - I could've installed it and been to California with it before he even knew it was gone!
OFD stands for Obsessive Fabrication Disorder. I like to make stuff, and the first step is going to be making an airbox and air filter housing assembly out of aluminum. I bought an airbox, thinking the air filter was in it (like my G). Finding out that the filter was seperate, I advertised for one and hunted around on ebay - no luck. 7981GS offered one as a template so I could make one, but Rustybronco is local to me and was cool enough to offer his for me to reverse engineer. I decided to make a new airbox out of aluminum too, so it would be easier to install and remove. This is what I came up with:
These are the three views. I tried to get the interior volumes of these boxes to match the originals as close as possible, so the air management would be close to stock. I can't see how a set of pods would improve the flow much over this system. Here is a better side view:
The stock air filter box had roughly 6 1/2 square inches of opening for air inlet into the box, so I will add (22) 5/8" diameter holes to replicate that. After designing the filter housing, I did a quick cardboard mock-up to make sure it would actually fit:
I will make better posterboard mock-ups before I start butchering up the aluminum.
The overall plan for the bike is to improve the suspension and make it a little better handling than stock. I am considering making an aluminum swingarm, and swapping on an inverted front end. Maybe some Works shocks, a different seat, etc. I am suspecting that the twisted "highway bars" were installed too tight and may have dimpled the frame, so I'm not too worried about destroying a museum piece. Overall the bike is in decent condition, and will be perfect for this project.
Once again - big thanks to Dale for trusting me and loaning out his air filter box. As fast as this bike is - I could've installed it and been to California with it before he even knew it was gone!
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