Weasel's 1978 GS750 cafe racer project

[Weasel]

Pretty slow going on progress. Took a week off and headed south to the beach & warm weather with the family.



Came home to the correct aluminum rails for the carbs with a few other goodies. I'll finish cleaning the outside of the carb bodies & get them put together & back on the bike this week hopefully.

[ttfraz]

What did you clean up those bolts with? Nice build

[Weasel]

What did you clean up those bolts with? Nice build

Thanks. I have a brass wire wheel on my bench grinder.

[Weasel]

Waiting on another round of parts from suppliers and from powder coat. Figured I would get my seat pan done so I can wrap this seat up. Walmart had the best prices on the Bondo brand of fiberglass products.



Masked off the frame and taped some newspaper along the sides to keep things clean.



Aluminum tape on, just need to prep my fiberglass kit and put a coat of wax on the tape.

[Weasel]

I had a chance tonight to get the fiberglass and resin on the seat pan. I cut out a rough single piece of cloth for the first layer then cut 3-inch squares for the 2nd & 3rd layers. A coat of wax on the aluminum tape & I'm ready to start glassing.

[Weasel]

The process went ok but I might have used too much hardener as it was setting up fast. I got 3 layers done and it looked pretty good minus a few air bubbles. I'll report back after it sets up.

[Weasel]

Seat pan turned out ok for my first one ever I suppose. It needs a little more shaping & sanding before I attach it to the bottom of the cafe seat/cowl I have here.

[Weasel]

Got the back tire removed & I have to finish cleaning up the wheels & hubs to get ready for powder coat. Can I have them powder coat the whole wheel or should I have them tape off the outside that will be under the rubber?

[ttfraz]

I just had mine powder coated and they did the inside. Didn't even think of it as a problem and they seemed to think it was normal procedure. If you are concerned about air leakage there will be tubes in anyways. If it's a tire sealing concern I believe it will be fine I assume at least on mine because of the minimal build up. All being said I have yet to throw them back together.

Do do you plan on reusing the spokes?

[Weasel]

I just had mine powder coated and they did the inside. Didn't even think of it as a problem and they seemed to think it was normal procedure. If you are concerned about air leakage there will be tubes in anyways. If it's a tire sealing concern I believe it will be fine I assume at least on mine because of the minimal build up. All being said I have yet to throw them back together.

Do do you plan on reusing the spokes?

No, most of these spokes are beyond repair. I will be ordering new ones. Got the back rim cleaned up and now both are ready for PC.

[Weasel]

Another round of parts went to powder coat today. The wheels will be getting coated in a metallic charcoal gray. The hubs, rotor centers, and calipers will be done in a metallic burgundy (similar to original color).

[Chuck78]

Looking good man, can't wait til you've resurrected this one and get it on the road! With some good shocks, cartridge emulators, modern Avon AM26/Pirelli Sport Demon/Shinko 230/Bridgestone BT45 Battlax tires, and a good engine tune, you'll have a very very pleasing machine to ride right there. Great classy looks, best handling of the 1970's bikes + your handling revisions, very fast...and you built it with your family.

They're fairly mild mannered below 4500rpm, but wow even giving it 60% throttle 3500+ and shifting at 6000rpm is a total blast. Any more throttle or any higher shifts than that seems like absolutely ludicrous acceleration on test rides around the neighborhood... running them 6000-9500rpm full throttle acceleration just feels like your riding a missile, the tach needle just darts to redline like lightning.
Fantastic handling vintage machines with the 3 mods I mentioned here. They sound REALLY REALLY killer with a Vance & Hines 4-1 or the MAC 4-1 with MAC's straight thru glass pack type performance baffle swapped in place of the chambered baffle that MAC gives as stock (chambered MAC is louder than stock but similar tone to stock, tame & not offensive to neighbors)

you'll be very pleased. I'm hooked. 1st (well, 2ND sorta) bike was a GS750 for me, still have it, + 1 in milk crates with titled frame, + 1 parts bike, +2 spare engines, +1 Rickman CR900 frame with the Z1 engine mounts converted to GS engine mounts and getting a spare GS750 engine built into a big bore.

All of the 8v 4cyl chain drive GS's are really awesome classic vintage machines. GS550, GS650E, GS750A/B/C/N/E, GS1000...

[Chuck78]

Oh don't forget to get the slightly longer than stock shocks if you haven't already.

[Weasel]

Thanks Chuck! Sounds good.

My PC guy was kind enough to media blast my gas tank. Wow, not a dent, mark or single sign of repair on a 38 year old tank! Got a few other covers back along with the fuel cap and door.

[Weasel]

Any suggestions on where to get replacement stock spokes? With charcoal metallic rims and burgundy metallic hubs should I go regular spokes or black?