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 gs550 7k miles cafe racer build

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carbon moto



Posts: 103
Join date: 2011-12-22
Age: 51
Location: sheffield s.yorks

PostSubject: gs550 7k miles cafe racer build   Sat Jan 19, 2013 9:50 am

Now the xbr project is 99% finished (just got a few silly bits to do & a photo shoot at the end of next week, will post pics)
We have now started another build, a 7k miles gs550 that's been in storage for most of its life.After cleaning the bike it is obvious that it is in very good condition no rust on the frame at all so its a good base for a cafe racer.
[img][/img]
We have quite a few gs550 5 or 6 ish so the idea is that we make this bike into a kit that can be bought to convert the 550 & 750 into a cafe racer with everything documented in the instructions, all fittings brackets etc included, this will be the test mule so to speak.
We are making a completely new seat for this bike,starting with foam & covering it with body filler with lots of saning to get the shape, my lad has put something like 15 hours into this already, then we can make a mould or 2 & knock some seats out,The look im wanting is similar to the next picture (nothing fits properly as we have to de lug the frame & make a new base for the manx norton tank to fit the gs frame then it will sit properly.
This one might even have a fairing
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gone fishin



Posts: 541
Join date: 2011-10-26
Location: black country

PostSubject: Re: gs550 7k miles cafe racer build   Sun Jan 20, 2013 11:33 am

nice shape tank Cool
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carbon moto



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PostSubject: Re: gs550 7k miles cafe racer build   Sun Jan 20, 2013 11:44 am

miffa wrote:
nice shape tank Cool
its a manx norton 5 gal tank
will be fitting a new bottom to fit the gs properly & loosing the last 4" nearest the seat
the battery will fit under that part of the tank
probably take it down to 4 gal then
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gone fishin



Posts: 541
Join date: 2011-10-26
Location: black country

PostSubject: Re: gs550 7k miles cafe racer build   Sun Jan 20, 2013 11:58 am

is it a full tank or cover scratch
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carbon moto



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Join date: 2011-12-22
Age: 51
Location: sheffield s.yorks

PostSubject: Re: gs550 7k miles cafe racer build   Sun Jan 20, 2013 1:25 pm

miffa wrote:
is it a full tank or cover scratch
its a tank mate
but i will be sectioning a battery sized area at the back making that a cover.
it will still look like the full sized tank until its taken off the bike
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beekeeper



Posts: 231
Join date: 2012-01-11
Age: 47
Location: poole, dorset, england

PostSubject: Re: gs550 7k miles cafe racer build   Mon Jan 21, 2013 1:24 am

is it a steel or glass fibre tank?

if the later, could you put your spin on our "what to line it with" debate.

by the way, already liking the lines of this one.
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carbon moto



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PostSubject: Re: gs550 7k miles cafe racer build   Mon Jan 21, 2013 3:01 am

beekeeper wrote:
is it a steel or glass fibre tank?

if the later, could you put your spin on our "what to line it with" debate.

by the way, already liking the lines of this one.

hi beekeeper
its out of fibre glass or carbon fibre, havent decided yet Very Happy
We use a very high chemical resistant (yes ethanol up to 15% too) resin to make our fuel tanks, its very expensive & a pain to work with needing heat to cure it for 8-10 hours gradually getting hotter up to 80c.
It works well as its what underground fuel tanks are often lined with.
it took me 2 years to find this product so id rather not say what it is.
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beekeeper



Posts: 231
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PostSubject: Re: gs550 7k miles cafe racer build   Mon Jan 21, 2013 6:54 am

fully understand.

pretty sure i'd say the same. Smile
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carbon moto



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PostSubject: Re: gs550 7k miles cafe racer build   Mon Feb 11, 2013 12:04 pm

Got loads done on this & the other 2 bikes im building.
This one will be known as gs550 7k miles
The other gs550 will be known as gs550 #2
& a gs1000 g shaftie i hate shaft drive Very Happy Very Happy Very Happy
Will make new threads for each bike
So here is what i have done on this bike.
Totally stripped it to rolling chassis, cut off all brackets that are not needed ie side panel, battery box, foot peg mountings

Not a lot left now.
Just collected a couple of swinging arms i have had modified by my lads mate,
gsxr600/750 alloy arms with twin shock mountings now welded on
The seat plug & mould made & a seat has come out of the mould ,looks good with the tank
will start the dry build tomorrow
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carbon moto



Posts: 103
Join date: 2011-12-22
Age: 51
Location: sheffield s.yorks

PostSubject: Re: gs550 7k miles cafe racer build   Sun Feb 17, 2013 11:07 am

Had a change of plan for this bike, it wont be using the ally swinging arm.it will be all standard running gear with the standard cast ally wheels.
The body work will be a Rickman tank, Rickman /Avon type fairing with one of our new design seats.
Just got the foot peg hanger brackets, fairing mount bracket & the seat mounting brackts to weld on the the frame gets blasted & can then go for powder coating,just plain gloss black, hopefully next week.
This is a rough idea of the look (the fairing is just sat on the fork tops)
ANY SUGGESTIONS ON COLOUR as im not decided on this one yet
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Pud



Posts: 359
Join date: 2011-06-06
Age: 47
Location: weeley, Essex

PostSubject: Re: gs550 7k miles cafe racer build   Sat Feb 23, 2013 2:07 am

looks good m8 what screen are you going to use with your half fairing
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carbon moto



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PostSubject: Re: gs550 7k miles cafe racer build   Sat Mar 02, 2013 11:51 am

Pud wrote:
looks good m8 what screen are you going to use with your half fairing

We have a company that make screens for the fairings we do, smoke or clear
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carbon moto



Posts: 103
Join date: 2011-12-22
Age: 51
Location: sheffield s.yorks

PostSubject: Re: gs550 7k miles cafe racer build   Sat Mar 02, 2013 11:51 am

just a quick update
the frame is all welded up, brackets removed & smoothed off, it has now gone for blasting & powder coating (yes im not painting this frame).
Will post pictures of it when it comes back.
have been getting on with the engine, cleaning it up ready for painting, all side cases off it now to be polished next week
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carbon moto



Posts: 103
Join date: 2011-12-22
Age: 51
Location: sheffield s.yorks

PostSubject: Re: gs550 7k miles cafe racer build   Fri Apr 05, 2013 11:59 am

Sorry for the lack of posts recently - we are extremely busy at the moment, work has been getting done but just not had a minute to post.
The frame , swinging arm, brackets etc have come back from the powder coaters - a company i have not used before but a mate recommended them, i can only say wow Excellent finish done quickly at very good prices by really nice people who do ring you when its done Very Happy (try them Metal magic @ barnsley s.yorks)

The colour is called titanium looks like a nickle finish.
The parts are coming together well, all bearings have arrived, just fitted swinging arm ones,just waiting for a big delivery of stainless fasteners then the assembly can begin.
also made a new seat unit for this bike & the mould is ready to make seats
more next week as it could progress quite quickly, should get the engine in during the week (hopefully)
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Pud



Posts: 359
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Location: weeley, Essex

PostSubject: Re: gs550 7k miles cafe racer build   Wed Apr 10, 2013 2:17 pm

looks good m8
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