My first cafe build

[StreetKing]

I got this 1981 GS450t off of craigslist for $300 because the owner said it would not start. I soon found it had an inline fuel valve installed and when I turned it on, the baby fired right up and purred. I immediately began the build. Everything done to the bike was a first-time attempt and I am quite pleased so far. The only purchase was the handlebars and mirrors. The seat, seat pan, rear cowl and side covers were custom made. I would like some opinions.


Current progress:

[Helmet Head]

Nice

Good work so far. Plans for the finishing touches?

[Broncoman75]

I think it's looking pretty good

but where is your tail/brake light? hard to tell if you've got one hidden on there somewhere or not..

[azr]

Don't want to hurt any 'L' feelings but man what a huge improvement. Good point about the brake light, sure doesn't look like there's one. Did you shape the tank yourself?

[pete]

Looks pretty damn good to me! Do you have some full side on shots and front/rear shots as well?

I experimented with side covers like what you did and gave it up as a bad joke... looks like you pulled it off nicely though!

[83_450E]

Looks like the seat has a nice cave for the balls to rest in. Nice!

[StreetKing]

but where is your tail/brake light? hard to tell if you've got one hidden on there somewhere or not..

I haven't gotten that far yet. I plan to use a simple round taillight and bullet signals.

Good work so far. Plans for the finishing touches?

Thanks..I plan to paint the frame white and add brown racing stripes and brown trimmings.

Don't want to hurt any 'L' feelings but man what a huge improvement. Good point about the brake light, sure doesn't look like there's one. Did you shape the tank yourself?

Thanks bro. Yes, I did the tank reshape. It was my first attempt at it. I'm pretty pleased with the result.

Looks like the seat has a nice cave for the balls to rest in. Nice!

it's nice and cozy for the boys

Looks pretty damn good to me! Do you have some full side on shots and front/rear shots as well?

I experimented with side covers like what you did and gave it up as a bad joke... looks like you pulled it off nicely though!

Thanks Pete. here's what I did: I cut off all the protrusions from the side of the frame. I relocated the relays and heat-sink looking thing to the top of the rear frame- under the rear cowl. I took masking paper and put it against the side frame and folded/creased and taped it to the shape of the frame. I then took the paper shape and laid it on one of those office-type florescent light covers I bought cheap at Home Depot, traced it with a sharpie and cut it out with an angle cutter. I planned to use the light cover itself, but it is very brittle and cracks when drilled. I then waxed it up and covered it with a single layer of fiberglass. Once it dried, I separated the pieces and took the fiberglass piece and drilled my mounting holes. (the mounting pieces I cut off were relocated and rewelded). After drilling the holes, I took painters plastic and taped it to the side frame to protect it from the next step of fiberglass. I mounted the side piece, bending it to the shape of the side frame, and applied another layer of fiberglass and let it dry. The fiberglass will not stick the the painters plastic, so it worked out well. After that, it was all about body filler and sanding smooth. I use 'Rage' body-filler...it's a bit pricey at $80 a gallon, but so worth it. It dries fast and sands easy. I finished it off with flexible door trim from autozone and put it on all the edges.


There are a few more photos here that were taken during the project:

https://plus.google.com/u/0/photos/103071123386324702917/albums/5884592127639316033

[pete]

Sounds like a good method to me! Looks like it worked out very well...

Just one thing with the "heat-sink looking thing"... this is your regulator/rectifier... it needs lots of air flow to keep it operating effectively. It would be better to mount it somewhere where it gets air rather than in the tail piece.

On mine, I put an electrics tray under the seat, and the R/R is mounted underneath that so it gets good air. I don't have sidecovers to block the air though...

[StreetKing]

Sounds like a good method to me! Looks like it worked out very well...

Just one thing with the "heat-sink looking thing"... this is your regulator/rectifier... it needs lots of air flow to keep it operating effectively. It would be better to mount it somewhere where it gets air rather than in the tail piece....

Thanks for the tip! I will def need to move it, then.

[steve murdoch]

Very nice work on the tank!
Can't remember seeing a custom bike with the stock pipes. That is usually the first thing to go.

[StreetKing]

Very nice work on the tank!
Can't remember seeing a custom bike with the stock pipes. That is usually the first thing to go.

Thanks! It is still in progress, but I think I may leave the stock pipes, after all. I like the look of them with the current mods.