Progress!!! 1978 GS1000E Restoration/Performance Rebuild

[gregzbutt]

Excellent work! I'm really digging all the pictures and detailed descriptions of your progress.

A write up on the zinc plating process would be great. I have been doing some research into getting some parts on my bike zinc plated. I may try to tackle this on my own now after seeing your work in this thread.

Mmm... Bike building supplements...

[JTGS850GL]

I'll be looking forward to the write-up. I know it's work but it's work that could live a long life and benefit others. Nice job so far.

[jameson079]

completely mind blown

[philosopheriam]

Thanks folks! Means a lot! I will post some more zinc plating photos tomorrow!

[philosopheriam]

Slowly working through a pile of old hardware....

IMG_1358 by Anthony Monteleone, on Flickr

IMG_1357 by Anthony Monteleone, on Flickr

IMG_1362 by Anthony Monteleone, on Flickr

[steve murdoch]

Nice looking wind chimes.
This has been a great restoration to follow.

[philosopheriam]

My $100 ebay blasting cabinet setup - actually, it's more like $150 one you add the blasting media and attachment I built to plug the shop vac into the side of the cabinet.
IMG_1365 by Anthony Monteleone, on Flickr

GS1000 steels turned down to match the diameter of an 1100 steel - I have an 1100 basket shaved to match the height of the 1000 basket. In order to keep the stock number of steels and fibers, the 1000 steels must have their OD's turned down on a lathe. 1100 steels are thicker than stock 1000 steels, thus, all of them won't fit inside a stock 1000 height basket once all of the fibers are installed. These are my old steels, so, I bead blasted them to make the finish uniform.
IMG_1366 by Anthony Monteleone, on Flickr

[GS-cafe]

thats awesome man, this is a true "nut and bold resto!"

[philosopheriam]

THE END IS NEAR :-) Lots of progress was made on 5/24 - cams were timed, clutch was installed, starter clutch was cleaned up and re-tightened, etc.

IMG_1376 by Anthony Monteleone, on Flickr

IMG_1377 by Anthony Monteleone, on Flickr

IMG_1378 by Anthony Monteleone, on Flickr

IMG_1379 by Anthony Monteleone, on Flickr

IMG_1380 by Anthony Monteleone, on Flickr

IMG_1381 by Anthony Monteleone, on Flickr

IMG_1382 by Anthony Monteleone, on Flickr

IMG_1383 by Anthony Monteleone, on Flickr

IMG_1384 by Anthony Monteleone, on Flickr

IMG_1385 by Anthony Monteleone, on Flickr

[philosopheriam]

Additional photos from 5/24...

IMG_1386 by Anthony Monteleone, on Flickr

IMG_1387 by Anthony Monteleone, on Flickr

IMG_1388 by Anthony Monteleone, on Flickr

IMG_1389 by Anthony Monteleone, on Flickr

IMG_1390 by Anthony Monteleone, on Flickr

IMG_1391 by Anthony Monteleone, on Flickr

IMG_1392 by Anthony Monteleone, on Flickr

[Fjbj40]

Cool! I am slowly getting the gear together to start learning how to degree cams. I have done lots of reading with lots left to read yet! It is going to be a learning process that's for sure.

Keep up the great work and awesome build man!!

[philosopheriam]

One VERY long day of plating today - but the results were worth it. Footpegs, mounting hardware, and seat hinge parts

IMG_1398 by Anthony Monteleone, on Flickr

[philosopheriam]

DRUMROLL PLEASE............................................ ..... Aside from a few minor things (bolts that need to be purchased, etc) the motor is finally DONE!

DONE DONE DONE!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!

Please forgive the "cloudy" looking engine covers - they have oil marks from my grubby hands and will be wiped down and re-polished with some MAAS cream in the near future.

Last day of assembly, 5/31/2015
IMG_1403 by Anthony Monteleone, on Flickr
IMG_1406 by Anthony Monteleone, on Flickr
IMG_1407 by Anthony Monteleone, on Flickr
IMG_1410 by Anthony Monteleone, on Flickr
IMG_1411 by Anthony Monteleone, on Flickr
IMG_1412 by Anthony Monteleone, on Flickr
IMG_1413 by Anthony Monteleone, on Flickr
IMG_1414 by Anthony Monteleone, on Flickr
IMG_1415 by Anthony Monteleone, on Flickr
IMG_1416 by Anthony Monteleone, on Flickr

[azr]

Wow, fantastic work. Congrats, that's got to feel pretty damn good.

[philosopheriam]

THE FINAL PRODUCT (before anyone points it out, there are several places where I didn't install gaskets and other small parts due to these items needing to be taken off/removed to install the engine in the frame. I installed these parts so I could take prettier pictures)

On her way home
IMG_1417 by Anthony Monteleone, on Flickr

I am obviously not a photographer
IMG_1418 by Anthony Monteleone, on Flickr
IMG_1419 by Anthony Monteleone, on Flickr

Better lighting
IMG_1420 by Anthony Monteleone, on Flickr
IMG_1421 by Anthony Monteleone, on Flickr
IMG_1422 by Anthony Monteleone, on Flickr
IMG_1423 by Anthony Monteleone, on Flickr

If anyone is curious, I built a 2-piece stand for the engine that bolts to the oil pan surface (thus, the oil pan is not installed) using some plywood and old 2x4's. Then, this stand can be bolted to a moving dolly which allows me to wheel the engine around my garage with ease.