Budget GS1000S rebuild. Not!!

[kiwimacchi]

Hi Aaronduke, obviously not enough practice, otherwise wouldn't have got a 'run' in it! Combination of too cold conditions and not heeding Wayne the Painter's advice to not go too heavy over decals in the intial tack coat. Plan on redoing clear tomorrow. Todays job is the seat base...

[ifly85]

Gorgeous paint! I love the tank photo. I don't think I had ever seen the tank top on that original scheme. Very cool.

[kiwimacchi]

Well, spent most of today on seat base. My original was pretty rotten-



I borrowed a fibreglass copy from GregT and made a mold and copy for myself after drilling the mounts etc off the original steel base. I molded a piece of 8mm ally into the mounting points for the hinges and catch.



Then it was onto fitting all the hardware to base. Put hinges on and had a trial fit.



Had to space the hinges with washers to get lines right...





Then on with the other brackets, before pulling the whole lot to bits so I can paint base black, will 'glass the bolt heads in place so everything can be stripped down again without taking upholstery off.



Took a lot longer than I thought, but don't all things that are worth waiting for....?

[John Kat]

Great job on the seat base!
I'm sure there is a market out there for these.
I would be first on the list

[GregT]

Great job on the seat base!
I'm sure there is a market out there for these.
I would be first on the list

The one i have which Ade copied came from a post classic racer in Auckland NZ. I've spoken to him since and he's reluctant to do more...

Now that Ade has a mould however....I've sold Aermacchi frame kits to Australia and Canada with fairings and seats made by Ade so he, by definition, does export quality work....

[busaash]

hi love your build thread very detailed please could you tell me what colour blue your using as i am doing a build in the uk and am doing a wes themed gs 750e framed build
thanks ashley

[MK3Brent]

Just curious, and I could look this up myself. (Figured why not.)

Is the rear brake disc the same diameter as the 82' ?

Wondering if the swap would be easy if one wanted to just get the 85 GSX wheels, brakes, and swap them in.

Job looks like it going great! Looking forward to more.

[Arronduke]

keep up the good work.
Spring is here now in NZ.

[kiwimacchi]

Well, finally more to add! I spent most of the winter working on the electrics, only had spark on 2-3 cyl. After much testing and swapping of parts, finally worked out the ign module was poked. Bought a second hand Dyna 2000 off Fleabay, didn't notice there was no trigger with it. Stupid, but only lost $30. Greg T came to the rescue and donated a stock one from his 'spares'. As extra insurance I wired the relay fix into loom to give more spark at startup. Then reassembled and installed carbs, LED indicators. I also fitted an R1 throttle tube, 1/6th turn. If it is too heavy I also have an R6 one which is 1/4 turn, much nicer than std, and fit straight into Suzuki handlebar switch. As Christmas (summer here) loomed I decided to repaint clearcoat as I wasn't satisfied with finish. To ensure minimal dust, I built myself a spraybooth in my garage. First I laid plastic floorprotective covering on the floor of garage, then using my race ezi-up, clothed it in plastic sheeting. Anyone seen 'Dexter' on TV? My booth closely resembled his special room for his victims- my wife wasn't too keen to accept my invite to 'come in'!!



This was a much better environment for painting, and am happy with all bits except tank! Long story short, 3 more attempts at tank later, am satisfied with the job. I put it back together, and then it's off to another seat guy. You guessed it! I'm not satisfied with the first seat job, but am confident next time it will be great.




Last couple of jobs, fit the headers, make up a secondary pipe and fit CF muffler. Then oil, and hope it goes!! It's been at least 2 years and to date i haven't ridden it- Can't wait!!

[kiwimacchi]

Hi busaash,apologies for the delay in replying- for anyone's interest, the blue is a Dupont Centari Colour 600 basecoat. Navistar Blue, Formula ID 4286538. Hope this helps. Also, would be willing to make seat base for anyone who is interested. A warning though- they require a minor amount of work around edges to line up with bodywork at back, original steel bumper brackets can be used, but you will need to drill the spot welds on your original rusty base and then rivet or bolt them onto the fibreglass base. I will mold 8mm aluminium into 'glass to enable original hinges and catch to be bolted on after drill and tapping to 6mm. Can make in black gel to save painting, but will be gloss finish. If there's any interest, I will work out a price.

[kiwimacchi]

Hi MK3Brent. Rear wheel came without disc, so off to wrecking yard for me! The one I used is from a 1200 Bandit I think. A lot of Suzukis are interchangable. Cheers, Adrian

[John Kat]

Hi busaash,apologies for the delay in replying- for anyone's interest, the blue is a Dupont Centari Colour 600 basecoat. Navistar Blue, Formula ID 4286538. Hope this helps. Also, would be willing to make seat base for anyone who is interested. A warning though- they require a minor amount of work around edges to line up with bodywork at back, original steel bumper brackets can be used, but you will need to drill the spot welds on your original rusty base and then rivet or bolt them onto the fibreglass base. I will mold 8mm aluminium into 'glass to enable original hinges and catch to be bolted on after drill and tapping to 6mm. Can make in black gel to save painting, but will be gloss finish. If there's any interest, I will work out a price.

I would be interested by one seat base!

[kiwimacchi]

Hi John, will work out price and get back to you- you are in France??

[John Kat]

Hi John, will work out price and get back to you- you are in France??

Yes I am in France.
It might be worthwhile checking the cost to post the seat base first...

[kiwimacchi]

Well, got seat back, trimmer made great job, have cut header pipe at collector box and welded a 2" secondary pipe on. Got headers back from Ceramic Coating today and mounted up. Looks great!







Just got to hook up fuel and vacuum lines and hope to get fired up this weekend. By the way, I have painted the front fairing and brackets, but wont be fitting them- I want it naked!!