GS 550E 1980 -cafe build

[cowboyup3371]

Can't wait to see how they turn out.

The last few weeks have been very busy and I am starting to see some real progress. This post documents the powder-coating of my wheels and other misc. parts. I have a friend that works at a powder-coating place so I got to get a behind the scenes look and help, all at a great price.

Starting point:


Sandblasted:


I even got to sandblast my small parts:


Wheels ready for powda (after being dipped):


First coat misty gold:


First coat baked:




Second coat transparent gold powder:


Next post will show finished product.

I'm working on electrical mounts. I want to place everything on a panel underneath the seat but there isn't much room. I ordered a new blade type fuse block which will update those and will allow me to fuse the horn and coil relay mods I'm doing. The r/r is going to mount in the air-stream to the underside of the panel. I'm just confused on one part. There is a small box with one fuse in it and I'm not sure of its purpose. I've checked the wiring diagram and it is called the output terminal. It looks like it fuses an alternate ground to the starter relay. Is this part necessary, and it if is just a fuse can I wire it into my new fuse block?

I made a little more progress today. I faced off the handlebar mounts and removed the old gauge mounting ears from the top tree.

I also drilled a hole so I can mount the new acewell gauge. It just need a bit more filing and then its off to get powdercoated.

I also finished the mounts for the seat pan. Its held in place by tool clips and fits nice and tight.


I ordered what should be the 2nd to last round of parts today (wheel bearings, jets, exhaust gaskets, and stainless brake lines).

Update: last week I cleaned the forks to a dull shine. I started with 220 grit and worked my way up to 800 for the brushed finish I wanted.

Broken down as far I will go for now.


Did some grinding on the frame:

I removed excess tabs and passenger pegs and supports. I am removing the center stand as well. I want to be able to have the option to carry a passenger. When I make rearsets over winter I'll include something.

I mocked up the left side bars.


The first run of the bridgeport after I rebuilt it (bought from a foundry where they left it outside for a year) It still needs more tooling and fixtures, final setup and digital readouts. I drilled up a bracket for my ignition and choke cable relocation.


This will sit under the seat, I could not stand having the choke on top of the triple tree.

And a quick placement of items to see how she looks.

What did you do with the stock exhaust?

Its currently hanging up on my wall, I plan on selling it. It has minor pitting throughout and is a bit worse around the crossover.

Ahhh very nice. I'm working on pretty much the exact same bike. I'm interested to see how yours comes out!

[cowboyup3371]

What did you do with the stock exhaust?

Are you planning on doing anything with that stock seat? If not, interested in selling it?

Unfortunately it was taken apart foolishly before I found this forum. When I first got the bike I planned on doing a quick cafe seat out of it (shortening and trimming foam). I took it all apart before but didn't damage it otherwise. I then realized that there was no easy way to narrow the seat and keep the hinges. So the project developed and will now include full custom seat and tail. I'll start selling stuff (sidecovers, tail, seat parts) after I finish the build unless someone on the forum wants to buy them. The cover had a few small tears through it but was otherwise okay.

Are you planning on doing anything with that stock seat? If not, interested in selling it?

[wegs426]

I've been lurking here for a few months and now that school is out I can finally dig into my first build and first bike.

I bought it off craigslist in early march, the guy was cool enough to drive it over to me. 1980 GS 550E:



These past months were spent taking a ton of stuff off the bike, researching info here, designing the build and ordering parts. I'm going for a modern cafe look.

My slew of parts:

mac 4-1 head pipe, pirelli sport demon front tire, K&N pods, hella horns, Custom LED taillight, turn signals, grips, clip-ons, headlight brackets, clutch lever, mirror, gaiters, acewell gauge, and shorai battery.
not yet received: muffler and MC from DCC

I'll update how she sits now tomorrow.