1982 GS300 Project - Where do I start

[hjacobmiller]

Oh, its so clean! Very nice!!!

Did you just use 14ga sheet metal to make that tray?

My seat pan will be here this week so I start brainstorming after I know what I have to work with.

I need to send Dynatek some more pictures of the installation - will have to take some more while I'm messing with the carbs.

[pete]

Nah that's 2.5mm aluminium sheet there. Had a huge sheet I made my front mudguard mount/fork brace out of and have heaps left still.

[hjacobmiller]

Nah that's 2.5mm aluminium sheet there. Had a huge sheet I made my front mudguard mount/fork brace out of and have heaps left still.

What is working with it like?

I don't have any metal working tools except a drill, pair of snips and some files so I have to keep that in mind for any modifications I do.

Oh I do have an amazing tool to remove rust with. It's called a wire brush. Ever heard of it?

[pete]

What is working with it like?

I don't have any metal working tools except a drill, pair of snips and some files so I have to keep that in mind for any modifications I do.

Oh I do have an amazing tool to remove rust with. It's called a wire brush. Ever heard of it?

I don't have much more than that to work with metal either... a hacksaw and a jigsaw with metal blades is about it...

I find it easier to work with than steel but I'm no expert at it, I only know what I've tried and made for the 450. What I've made from either 2.5mm or 1mm aluminium is:

Front mudgard mount/fork brace
Dash/Acewell bracket
Acewell speed sensor mount
Battery box cover
Electrics tray
Tool tray under the tail piece

Oh, and what's better than a wire brush is a wire wheel on a drill or bench grinder... they work well

[hjacobmiller]

I don't have much more than that to work with metal either... a hacksaw and a jigsaw with metal blades is about it...

I find it easier to work with than steel but I'm no expert at it, I only know what I've tried and made for the 450. What I've made from either 2.5mm or 1mm aluminium is:

Front mudgard mount/fork brace
Dash/Acewell bracket
Acewell speed sensor mount
Battery box cover
Electrics tray
Tool tray under the tail piece

Oh, and what's better than a wire brush is a wire wheel on a drill or bench grinder... they work well

Definitely. I used a cup-end brush to clean up the inside of my head light bucket:

[pete]

Cool, they make it a lot easier! That's how I prep'd my wheels for paint too...

[hjacobmiller]

Photobucket's back up, here's my tray:



Everything grounds to a single point and one of those wires goes to battery negative:



Everything except the indicator relay is underneath:

I really like stashing it all on the bottom side of the seat and open. Gives the r/r a chance to get some airflow and cool off.

My seat pan should be here today and I hope it gets here soon enough I can tear off all the old crud and get it down to just the plastic pan.

I was thinking about what I could with the battery. Depending on how thick the seat pan is I was thinking about chiseling it out and then setting the battery in there, drilling a hole through the bottom to run leas through and then sticking everything on a tray like yours.

Since its a sealed AGM battery I can put it in sideways right? I may not even need to if I go with a hump in the back. I believe the L style pan gives me some thick area to work towards the rear.

Is that the mail man knocking?!??

[pete]

I really like stashing it all on the bottom side of the seat and open. Gives the r/r a chance to get some airflow and cool off.

My seat pan should be here today and I hope it gets here soon enough I can tear off all the old crud and get it down to just the plastic pan.

I was thinking about what I could with the battery. Depending on how thick the seat pan is I was thinking about chiseling it out and then setting the battery in there, drilling a hole through the bottom to run leas through and then sticking everything on a tray like yours.

Since its a sealed AGM battery I can put it in sideways right? I may not even need to if I go with a hump in the back. I believe the L style pan gives me some thick area to work towards the rear.

Is that the mail man knocking?!??

Yeah I was hoping to get some extra air flow with the R/R under there, especially with the cheapie from Hong Kong.

You should be able to do something with a smaller sealed battery although I just made a lockable cover for mine in the standard location.

I don't think the E pan gives as much room underneath...

[hjacobmiller]

Well my new seat came today and I mounted it on there. I think it looks great. What do you guys think?



It was in SUCH great shape when I got it too!





OK - so here is the pan. Not at all what I was expecting the innerds to look like. I thought the actual pan was 3-4 inches thick because of the hump in the back. Wrong.



Not worried though because I think this actually gives me a good place to start.

I need to pull all the old staples out and wash it before I do anything. It definitely has seen better days.

Hmmm... Wish I had more time to start getting into this...

[pete]

That should give you lots of flexibility to get it to the shape you want... nice!

[razor02097]

Cool man looks like you have a lot to play around with.

[hjacobmiller]

Thanks!

So you guys don't think I should leave it how it is?

This may be kind of random, but what are these?

http://www.ducati.ms/forums/attachments/sport-classic/91778d1308493088-new-rear-shocks-hyperpro-856459_produktefederbeine46736702.jpg

[pete]

They're called shock absorbers... they attach between your swingarm and frame to soften the ride...

Sorry, couldn't help that... hahahaha

Not sure, haven't seen those ones before...

[hjacobmiller]

They're called shock absorbers... they attach between your swingarm and frame to soften the ride...

Sorry, couldn't help that... hahahaha

Not sure, haven't seen those ones before...

Thanks... Ha ha ha. I didn't know what the can on the back is for. I was just curious as to what purpose it served or what was special about the kinds with those on the back.

Didn't know if it was some sort of Inspector Gadget oil gun out the back to slip up any trailing villians or something

[BigD_83]

That's a piggyback reservoir, increasing the cooling capacity of the shock.