GS 550E 1980 -cafe build

[green2kgt]

lookin good!!!!!!!! really liking some of the things you did. giving me ideas!

I love powder coat!!!!!!!!!!!!!!! im addicted to it! lol.

All the black in the pic below was silver on the bike originally... nothing was black from the factory.

http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash4/472790_10150940123348360_1012181400_o.jpg

[wegs426]

that's an insane attention to detail green2kgt, do you have a link to your build thread? I'm assuming it's on a different forum.

Today I finished making the rest of the brackets I need, this includes a hazard switch bracket, horn bracket and taillight bracket.

This is the horn bracket.




I even got it installed. These are horns that a lot of the Subaru rally guys use, they should be really loud and piercing at 118 db.


In this picture you can also see the tachometer delete plug.


I also started work on the tank. Before:


Mark the area to dent on paper then cut out 2 copies and tape to each side.


you can remove the paper after you get a good outline.




Here it is mounted and partially stripped. I've got a bit more smoothing to do and I need to go deeper on the right side but it's starting to look like a cafe racer. I may need to do bar dents too.

[wegs426]

Big updates: I've made a lot of progress over the last month, although not as much as I would have liked, my budget went over and I had to put in extra hours to get money to finish the build.

I finished cleaning the engine up and installed the headers and slipped on the muffler. This is going to be loud (may need a baffle).

Installed new chain.

Made and installed new cables. What a pain this turned out to be. I ended up losing the little plastic bushing thing on the end of the clutch barrel. It flew off while I was trimming the cable and went somewhere in my garage. I spent 2 hours looking for it with no luck, also can't seem to find one online.

Finished the electrical:
Wire nutted everything together for a test. Worked with just a few issues I had to chase. Wired in for coil relay and horn relay mods.



the taillight is super bright and the horns super loud.






Cleaned everything up, shortening where necessary and installed a few new connectors.




note: still have to wire in turn signals (broke one while mounting) and wire in license plate lights once I figure out a mount.


Rebuilt the carbs:
When I bought the bike the p.o. said it was't running properly and had trouble at low idle.

Opened them up to find 3 broken float posts JB welded together...
Luckily with the bike came a box full of a disassembled set of carbs and spare parts. The disassembled carbs were good except for one post. I was able to make a full set with only one nicked post (just above hole was sheared off).



box of parts that saved me:

I may end up building a second set of carbs to sell once I repair all the posts.

Also upon disassembly there was a missing washer on the main jet, I'm assuming this was what was the cause of the trouble.

The parts got the dip and o-ring treatment, new larger jets, and I'm just waiting on pilot jet plugs.



I cut foam for the seat.



I'm in the process of making a fiberglass cafe seat bubble. This will be removable so that the seat can hold two people.

I cut up an old polystyrene cooler and glued it together. I shaped it with a bread knife and 36 grit sandpaper. This makes a huge mess.



Once I had the shape I wanted covered it in tape it and waxed it.

I've got one coat of fiberglass and epoxy and its already pretty strong, I plan doing three total.

The bike should be finished early next week!

[bakirkwold]

Looking good! Those wire nuts are an automotive no no. I am going to school to be an automotive technician. Either solder them in or use crimp connections.

[nikosg]

great thread!!!! love your work.

[wegs426]

Haha, there are no more wire nuts on the bike. They were on only so I could test everything. The wires were shortened and soldered together. I have the burns to prove it.

[SOCKinside]

It's looking great, keep us posted

[wegs426]

Exciting day yesterday. I had the motor running last night for about a minute before the floats emptied. Sounds good.

Also picked up my license plate. Now Its just paint prep and paint.

[wegs426]

Here she is. The paint was such a headache, I'll update later with the process and issues encountered. All that's left for now is upholstery, which will probably have to wait a few weeks.

[ClineDesign]

Like it a lot, is that the Dime City stainless shorty muffler?

[wegs426]

Yeah, It was a little pricey but I didn't have many options with the 2.5" header. I may end up welding a baffle in at some point.

[ClineDesign]

Yeah, It was a little pricey but I didn't have many options with the 2.5" header. I may end up welding a baffle in at some point.

So how noisy is it?

[wegs426]

So how noisy is it?

It's actually not too bad at idle, but perhaps I haven't got sick of it yet.

[MAJikMARCer]

Looking good so far. What are the plans for the seat. I can't imagine with all the other work you've done that a couple slabs of neoprene are the final solution.

[ChicagoBob]

So, what's that rear cowl made from?