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Blood Sweat Tears and Grease => Projects => Cafe Racers => Topic started by: yozzer74 on Aug 10, 2016, 08:12:12

Title: Gs550 Scrambler
Post by: yozzer74 on Aug 10, 2016, 08:12:12
Hi this will be my second project .my first is almost complete now .so been looking round for a new project .this came up in my area .so thought I would give it ago .looks a bit strange at minute but I'm hoping to make a brat / scrambler out of her .
Title: Re: Gs550 brat i hope
Post by: yozzer74 on Aug 10, 2016, 08:18:11
When I got her home found tank doesn't fit at all .it was just wedged on to bike . I bought it as a none runner .but a couple of hours on it had her up and running .sound pretty nice https://youtu.be/ONDG1xKITKs
Title: Re: Gs550 brat i hope
Post by: yozzer74 on Aug 10, 2016, 08:24:11
So progress will be slow on this till my other bike is finished.but I did manage to find a tank for it .and picked some new bars up too from a auto jumble .this is bike as it stands now .
Title: Re: Gs550 brat i hope
Post by: tbagginz on Aug 10, 2016, 11:02:48
Wow looks 10x better already!
Title: Re: Gs550 brat i hope
Post by: yorkie350 on Aug 10, 2016, 13:38:34
Great second project yozz mate ime in for this one , sure got plenty of scope for making it your own , great to have a running bike to start with too that's a result already keep the updates coming mate .
Title: Re: Gs550 brat i hope
Post by: hillsy on Aug 10, 2016, 20:58:02
WTF are those pipes off?


I'm assuming GS750/1000 by the look of the height of them....
Title: Re: Gs550 brat i hope
Post by: yozzer74 on Aug 10, 2016, 23:27:47
Ha I'm told there off an old British bike but not sure which .
Title: Re: Gs550 brat i hope
Post by: yozzer74 on Nov 01, 2016, 17:46:35
Bought another Gs has a parts sauce for this build it's a katarna model so discs don't need drilling there already sloted .I'm thinking of using the frame as its already been cut .does anyone no if the frames are the same .also tried different tanks to see which looks best for scrambler look I'm going for
Title: Re: Gs550 brat i hope
Post by: yozzer74 on Nov 01, 2016, 17:52:23
Thinking I will stick with green one
Title: Re: Gs550 brat i hope
Post by: yozzer74 on Nov 01, 2016, 17:54:18
Now my Cb is finished I can get going on this build now so hopefully updates will be more often .
Title: Re: Gs550 brat i hope
Post by: yozzer74 on Dec 31, 2016, 12:00:31
Not really got much done on bike busy with DIY and Christmas .but have managed a little time on bike got all frame de'tabed and paint stripped off the petrol tank .also had wheels and discs sand blasted at work
Title: Re: Gs550 brat i hope
Post by: yozzer74 on Feb 24, 2017, 19:25:40
Been a while since I posted in this thread not got much done really just buying parts going with Motogadget m unit and switches m button . Had my wheels powder coated . New tyres fitted & bearings .
Title: Re: Gs550 brat i hope
Post by: yozzer74 on Feb 24, 2017, 19:31:11
Bought some nice old shockers off eBay need some work but think they look cool . Built bike back up to see what size to make seat pan and mock rear mudguard up .
Title: Re: Gs550 Scrambler
Post by: yorkie350 on Feb 25, 2017, 07:48:24
Looking good yozz mate every bit helps towards finish line ha that's wot I tell myself too ,got a gs550e "78 on the go myself gonna be another café style I reckon with a few modern updates swapped my front end for a 650 cos its got the slotted twin discs and better calipers too, your wheels look awesome decent boots gonna last a while I would think don't look cheap tho ,  have you thought about a colour scheme yet , keep updates & pics coming mate .
Title: Re: Gs550 Scrambler
Post by: Drey6 on Feb 25, 2017, 08:35:24
Nice snag on the those Marzocchi piggybacks, I was actually looking at that exact set! Unfortunately I didn't have the spare cash to justify it. Xb(Kenny) is a user that used to be on this forum is a known rebuilder of quality classic suspension. If you need his number shoot "Chuck78" a PM on here, I think he has it.


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Title: Re: Gs550 Scrambler
Post by: yozzer74 on Feb 25, 2017, 17:14:48
Yorkie I've been following your gs build I've got front end off  a katana 550 so have the slotted discs .  Not sure on colour yet but I'm 99% that it will be Matt thinking greys or light blue .drey6 got them shockes for a good price thanks for info on rebuilding them ..
Title: Re: Gs550 Scrambler
Post by: Rider52 on Feb 25, 2017, 17:31:52
This is going to be a great bike.
Title: Re: Gs550 Scrambler
Post by: yozzer74 on Feb 25, 2017, 17:35:37
Hope so rider52 I'm going to mount battery under swing arm m unit under seat but I don't want to see the tray from side of bike so going to have it going up into seat base .
Title: Re: Gs550 Scrambler
Post by: yozzer74 on Feb 25, 2017, 19:35:26
Hoping to mount it here
Title: Re: Gs550 Scrambler
Post by: yozzer74 on Mar 02, 2017, 13:30:29
Parts  mounting up now started painting discs up
Title: Re: Gs550 Scrambler
Post by: yozzer74 on May 05, 2017, 17:42:12
Been a while but some progress at last . Had the tank modified were the petrol flap was that covered the filler up . Had it plated and a monza cap fitted .also loop fitted and rear mudguard made . Plus a tray for m unit  and cdi box . And seat base
Title: Re: Gs550 Scrambler
Post by: Bootsey on May 06, 2017, 01:24:55
Nice, the fab work on the frame looks sweet!
Title: Re: Gs550 Scrambler
Post by: yozzer74 on May 07, 2017, 11:20:57
Today's action bit of fork polishing before and after photos  just wanting a satin finish on them
Title: Re: Gs550 Scrambler
Post by: yozzer74 on May 07, 2017, 14:36:22
Also started on rear shocks .
Title: Re: Gs550 Scrambler
Post by: Drey6 on May 07, 2017, 16:50:39
Lookin good brotha. Nice shocks, didn't notice these in the earlier posts- must have joined late!


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Title: Re: Gs550 Scrambler
Post by: yozzer74 on May 07, 2017, 17:15:57
Yeah got them off eBay .
Title: Re: Gs550 Scrambler
Post by: yozzer74 on Jun 04, 2017, 08:22:22
Bit more polishing done was going to get calipers powder coated but think they look good in bare alloy so going to go with them like that
Title: Re: Gs550 Scrambler
Post by: HDJ80 on Jun 15, 2017, 20:11:14
That is a nice job on the polishing.
You have convinced me to do the same with my 81 GSX1100 project.
Title: Re: Gs550 Scrambler
Post by: yozzer74 on Jul 09, 2017, 16:49:46
Well got round to finishing other two discs for front wheel . On my last build I spent a lot of money on titanium bolts . I'm not going down that road again with this build . I'm using stainless bolts . But I don't like how they have numbers and letters on the tops so out with the file and sand paper  . Then finished with scotchbrite pad .
Title: Re: Gs550 Scrambler
Post by: yozzer74 on Jul 25, 2017, 16:45:08
Got frame back from one off welding hes done all work on frame and tank .modified foot pegs and break & gear leaver . Relocated rear master cylinder got to get a different master cylinder yet.hes done a  Great job as usual started dry building it up few pics  .also relocated battery under swing arm along with reg /rec
Title: Re: Gs550 Scrambler
Post by: coyote13 on Jul 25, 2017, 16:54:11
Looking good!  Interested to see what you do with the seat foam and cover with that hump in it.  You're certainly doing it the right way as far as clearance!
Title: Re: Gs550 Scrambler
Post by: yozzer74 on Jul 25, 2017, 17:11:29
Spent a lot of time getting clearance right . I know a lot of people don't think about it
Title: Re: Gs550 Scrambler
Post by: BillyGoat4130 on Jul 26, 2017, 10:09:11
Super work, machine has a great stance!
Title: Re: Gs550 Scrambler
Post by: yozzer74 on Jul 27, 2017, 00:35:38
Thanks billygoat
Title: Re: Gs550 Scrambler
Post by: bimizz on Jul 27, 2017, 08:37:27
hii nice build i started a suzuki gs450 to make it caferace i almost finished but im having trouble to start it i dont know what is happening it doessent crank at all im thinking that the ground wires arent good assembeld and im sorry for my bad english please someone help me
Title: Re: Gs550 Scrambler
Post by: yozzer74 on Jul 27, 2017, 19:47:30
Is your battery good does it click when you try to start it .
Title: Re: Gs550 Scrambler
Post by: redstripe89 on Aug 06, 2017, 00:25:18
Today's action bit of fork polishing before and after photos  just wanting a satin finish on them

came out great, what was your process?
Title: Re: Gs550 Scrambler
Post by: yozzer74 on Aug 07, 2017, 07:49:30
 I started with 200 grit and worked up to 1000 grit then used scotchbrite pad on them
Title: Re: Gs550 Scrambler
Post by: yozzer74 on Aug 11, 2017, 11:58:13
Bit of a change of plan got the chance of some spoked wheels.so bought them very hard to find with disc on back it's from a gs 750 .going to powder coat rims and hubs and have stainless spokes..
Title: Re: Gs550 Scrambler
Post by: yozzer74 on Aug 12, 2017, 07:19:58
 Wheel bolt straight on e everything lines up with original spacers
Title: Re: Gs550 Scrambler
Post by: Drey6 on Aug 14, 2017, 12:09:30
If you are rocking the wood plank struts I'll take those Marzocchi off your hands! I'll even pay shipping....


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Title: Re: Gs550 Scrambler
Post by: Drey6 on Aug 14, 2017, 12:10:01
Bike looks great BTW.


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Title: Re: Gs550 Scrambler
Post by: yozzer74 on Aug 14, 2017, 17:00:09
Sorry mate already sold them
Title: Gs550 Scrambler
Post by: Bustermonkey on Aug 14, 2017, 17:46:59
Hi yozzer74. Im not hijacking your post, I just thought I would send you a couple of pics of my GS550e with the wheels on I bought off you. Its taking its time getting done but Getting the wheels has spurred me on.
 (https://uploads.tapatalk-cdn.com/20170814/f43a4db06df21c1fc0907c6f9987b501.jpg)
(https://uploads.tapatalk-cdn.com/20170814/312eb4d5270c6beb8891860273046eeb.jpg)


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Title: Re: Gs550 Scrambler
Post by: yozzer74 on Aug 15, 2017, 03:58:58
Hi sorry I missed you when you came for wheels .Your bike looks well very simular  to mine .hope your happy with wheels .
Title: Re: Gs550 Scrambler
Post by: yozzer74 on Sep 08, 2017, 20:26:47
Got my rims and hubs back from powder coating today off to be spoked up tomorrow. Also had seat base done and yokes going to have frame same colour  .it's Matt black with a sparkle in it .
Title: Re: Gs550 Scrambler
Post by: yozzer74 on Sep 08, 2017, 23:48:20
Also started working electrics out I dreaded this on my last build but I quite like doing it now .it's ok when you get your head around it
Title: Re: Gs550 Scrambler
Post by: yozzer74 on Sep 08, 2017, 23:57:03
And a bit more nut action lol.just working my way through all the bolts on bike .think they will look the nuts when frame as been powder coated
Title: Re: Gs550 Scrambler
Post by: teazer on Sep 09, 2017, 08:24:15
Very nice.  They now need to be plated to stop them from rusting.
Title: Re: Gs550 Scrambler
Post by: yozzer74 on Sep 09, 2017, 19:46:28
There stainless steel !!
Title: Re: Gs550 Scrambler
Post by: yozzer74 on Sep 15, 2017, 15:40:16
Trying front mudguard  in different positions which looks best low or high
Title: Re: Gs550 Scrambler
Post by: yozzer74 on Oct 01, 2017, 15:53:15
Thanks for the comments guys !! Do you ever feel like your talking to your self .
Title: Re: Gs550 Scrambler
Post by: HansS on Oct 01, 2017, 17:47:54
Looks awesome. The frame mods looks great, really nice welding and the details are just perfect. Love the spoked wheels. Wish I had a pair for mine. Keep up the good work👍

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Title: Re: Gs550 Scrambler
Post by: yozzer74 on Oct 01, 2017, 17:51:59
We're do you live I could put you in contact with someone that as a pair
Title: Re: Gs550 Scrambler
Post by: yozzer74 on Oct 01, 2017, 19:28:27
Got a bit more worked out with the wiring https://youtu.be/WDUHjK40GG8
Title: Re: Gs550 Scrambler
Post by: yozzer74 on Oct 03, 2017, 16:12:35
More work done on wiring today finished wiring m switches all wires hidden in bars .started working wiring out for battery box under swing arm .reg /rec also under there
Title: Re: Gs550 Scrambler
Post by: schenk on Oct 04, 2017, 03:09:25
Nice work so far man! Really digging the new wheels and clean wiring.
Keep up the good work
Title: Re: Gs550 Scrambler
Post by: brownballin on Oct 04, 2017, 19:30:48
so personally-go high with the front fender
and any way you can give dimensions of the battery box when your done, id like to try one for my CL 350
Title: Re: Gs550 Scrambler
Post by: yozzer74 on Oct 04, 2017, 20:29:37
The battery box I had made I just found smallest battery I could that would do the job and made it a round that .I can give you the dimensions if you like .
Title: Re: Gs550 Scrambler
Post by: yozzer74 on Oct 05, 2017, 20:40:45
Another part arrived today ordered from the USA. 8 days to get here not bad .k&n filters .
Title: Re: Gs550 Scrambler
Post by: yozzer74 on Oct 05, 2017, 20:43:30
Got to say they are a really tight fit in fact they are touching the frame .think they should be ok .
Title: Re: Gs550 Scrambler
Post by: yozzer74 on Oct 06, 2017, 16:21:11
Got seat back today
Title: Re: Gs550 Scrambler
Post by: yozzer74 on Oct 17, 2017, 16:16:22
Got a bit more done on wiring new coils arrived so fitted and managed to get her running .exhaust not fitted right .but she fired up straight away. When petrol got through https://youtu.be/wfr8WS7g8l8
Title: Re: Gs550 Scrambler
Post by: yozzer74 on Oct 24, 2017, 17:39:18
I've had some engine covers made think they will look well when engine is painted
Title: Re: Gs550 Scrambler
Post by: doc_rot on Oct 25, 2017, 03:03:53
very nice. might be worth painting them black and brushing the logos for some contrast. looks good!
Title: Re: Gs550 Scrambler
Post by: yozzer74 on Oct 25, 2017, 04:45:55
Doc rot I was thinking the same  :)
Title: Re: Gs550 Scrambler
Post by: yozzer74 on Nov 14, 2017, 11:58:44
The guy making my pipes just sent me some pics of them .Think they look great .