82 GS450E Scrambler from Aus - Done!

[peteGS]

I wish there was a "thumbs up" face - that would take care of half my posts in this thread........

Great idea putting the indicator back in along with a voltmeter. Can you switch the clock for 24 hour to 12 hour? Or is that a personal preference?

Haha yeah they definitely need one of them, could've used a few in your thread actually!
 
I'm hoping it all works out as neat as it appears in my head... and yeah there's a setting on the Acewell to switch between them, but I've always preferred 24 hour time for some reason.

[Hoosier Daddy]

Code: [Select]

[img]http://www.city-data.com/forum/members/jill61-603505-albums-emoticons-pic61295-th-smiley-two-thumbs-up.gif[/img]
gives you this...
 

[peteGS]

Hahahah nice one HD!



As for me...


Got the bottom bracket bent tonight and the top part bent to form the box as well:





So it should end up looking something like this:





Next up will be getting the mounts sorted so I can test fit it all.


No sign of the voltage meter yet but it's a bit early, so will organise that once it gets here. Plenty to do in the meantime...

[MILLENNIUM FALCON]

Looking good man! That should work nicely for you.

[peteGS]

Looking good man! That should work nicely for you.

Cheers mate! It's coming together slowly.


I got a couple of holes drilled tonight for mounting the gear position indicator but that's about it, so no pic's at the moment.


I'm at the fiddly bit of working out where to put all the mounting posts and holes so I don't mess it up and have to start over from scratch.


I'm also still waiting for the voltage monitor to arrive from the UK so I can work out where it's going to sit.

[SoyBoySigh]

Damn, I had no idea that these old bikes even HAD a gear position indicator. One thing that I do know of having such a gizmo, would be some of the slightly more expensive Acewell gauges. Ha ha. I am sure you've been over this, but I just had to say it. I really like your build in any case, that scrambler pipe is bad ass. I would just love to throw one like that on my '82 CB750F. It's just brilliant. You know what I love on a high pipe though, that just screams "VINTAGE!!!" would be those little pipe guards. I had an SL100K1 when I was 16, back in '90 (and a CB100K0 from which I made a hybrid, using both rear rims, and the high pipe of course.... My damned neighbor stole the engine when I was in the middle of my move though. I went back up North to get the bike I'd been working on for months in a basement for cripe's sake, and the house hadn't been sold yet, I was just running back and forth. He'd asked me repeatedly if he could buy the engine for his kid's go-kart. One day, I am going to wind up in prison over this whole tale, so I should be careful what I say here.... Ha ha. It was a newly rebuilt engine and everything. Ugh.....) Anyway, yeah I just LOVED the guard on that old pipe. If I manage to fit up a high pipe, I'm looking at the awesome, new, and affordable, four into two into one from Cycle Exchange, and they have a plain header so you can fit up what you want to it. That's so cool. What would be even cooler, would be an "EXUP" valve down there too.... But yeah, it's GOTTA have a guard on it. Anyway, that's my two bits. Kinda feeling your frustration there over the gear indicator ... I can't even READ mine, and it doesn't even MOVE ... it's just carved into my sprocket cover on the left side of the engine where as hard as I crane my neck I can't read it. But it still works, if you get my meaning. Ha ha. But yeah, THAT, AND absolutely loving your scrambler exhaust. Too freakin' cool.

-Sigh.

[peteGS]

Damn, I had no idea that these old bikes even HAD a gear position indicator. One thing that I do know of having such a gizmo, would be some of the slightly more expensive Acewell gauges. Ha ha. I am sure you've been over this, but I just had to say it. I really like your build in any case, that scrambler pipe is bad ass. I would just love to throw one like that on my '82 CB750F. It's just brilliant. You know what I love on a high pipe though, that just screams "VINTAGE!!!" would be those little pipe guards. I had an SL100K1 when I was 16, back in '90 (and a CB100K0 from which I made a hybrid, using both rear rims, and the high pipe of course.... My damned neighbor stole the engine when I was in the middle of my move though. I went back up North to get the bike I'd been working on for months in a basement for cripe's sake, and the house hadn't been sold yet, I was just running back and forth. He'd asked me repeatedly if he could buy the engine for his kid's go-kart. One day, I am going to wind up in prison over this whole tale, so I should be careful what I say here.... Ha ha. It was a newly rebuilt engine and everything. Ugh.....) Anyway, yeah I just LOVED the guard on that old pipe. If I manage to fit up a high pipe, I'm looking at the awesome, new, and affordable, four into two into one from Cycle Exchange, and they have a plain header so you can fit up what you want to it. That's so cool. What would be even cooler, would be an "EXUP" valve down there too.... But yeah, it's GOTTA have a guard on it. Anyway, that's my two bits. Kinda feeling your frustration there over the gear indicator ... I can't even READ mine, and it doesn't even MOVE ... it's just carved into my sprocket cover on the left side of the engine where as hard as I crane my neck I can't read it. But it still works, if you get my meaning. Ha ha. But yeah, THAT, AND absolutely loving your scrambler exhaust. Too freakin' cool.

-Sigh.

Hahaha thanks mate! I love that pipe too, it's usually the first comment on get on the bike before they either walk away or look further. I've had compliments on it from people I never thought would even give it a second glance so that's pretty cool
 
I'm actually glad I'm keeping the stock gear indicator, it will make the Acewell look a little less modern once it's mounted up beside it, and yeah those other Acewells aren't exactly cheap! I think only the rectangular ones have that feature also which wouldn't suit what I want...
 
Always in the back of my mind is thoughts of a CL or DT (I think) style heat shield for the pipe, but if I ever do it'll be a while away... something neat and chromed would be the way to go
 
You'll definitely have to post up pic's if you do that with the CB!

[peteGS]

Ok, I've managed a bit more progress over the last few nights and bits of time here and there, and it's at the point where it's basically all there and just needs a tidy up and smoothing etc.


I'm still waiting for the voltage monitor to arrive and that's the bit that's gonna kill progress very soon until it gets here.


So, mock up of how it should look with the gear position indicator:





Cut the mounting posts to size:





I filed them down smooth and to the exact right length after the photo.


All mounting holes drilled:








Test assembly:





I'm not using the cap head bolts in the final version, I'm waiting on some button heads to arrive instead. They were out of stock at the time but I needed to get something to test with and cap heads were all they had.


And mock up mount on the bike, and I have to turn the Acewell upside down while it's still mounted on the old bracket:





And I got the perspex cut basically to shape and here's the test fit with it as well:





Getting very close now...

[peteGS]

Ok, close to as far as I can go before the voltage monitor arrives. Got some 60 grit sandpaper out tonight and smoothed all the edges off and got the acrylic perspex down to the right size and shape.


Gave the whole dash a go over with 240 grit to get it all smooth as well.


Aside from the voltage monitor mounting, the last thing I'll need to do is get some JB Weld going to fill up some gaps the bending has left in the corners and then it should be good to paint and assemble.


I really wish that voltage monitor would get here!

[Cafe Redneck]

Great job, Pete!!! Vast improvement over those big ugly ass Suzuki gauges.

[peteGS]

Great job, Pete!!! Vast improvement over those big ugly ass Suzuki gauges.

Thanks mate, certainly is! More done tonight and she's almost ready for paint...

[peteGS]

Ok, so the button head stainless bolts and the voltage monitor arrived today.





So I gave the voltage monitor a little run on my test setup with variable voltage and it all worked like it should, and I tried with the link installed and it will definitely double as a battery monitor as well. Nice, very happy with that!


One of the guys over on the GSR suggested I add a momentary switch to switch it over into battery monitor mode, and that idea is going ahead:





That's just a momentary push button mounted underneath to keep it away from the weather as I couldn't find a small enough weatherproof one.


Basically, holding that in while I turn the key on will put it in battery monitor mode instead of voltage monitor mode. Simple.


So, given I have the perspex cover over the dash, I needed to recess the monitor under the perspex, so I made a little bracket to mount it to the lower part of the dash. I need to adjust it a bit as you'll see later on:





And the final mock up:





And some quick final testing:





If you look closely you'll see the LED for the voltage monitor is a little too far left and low for the hole, which is what I alluded to in the earlier comment about needing to adjust the bracket. Should be easy.


And a quick couple of videos, first in over voltage condition:





And in under voltage condition:





So, once I adjust the bracket for the monitor, it's out with the JB weld finally to seal up the gaps and do a general tidy of some marks and things, then it'll be sand, clean, etch primer, then paint.


Can't wait for it to be done!

[Big Rich]

This is coming along really well Pete. I haven't been on the GSR much lately, but I'll have to read the details over there as well.

[peteGS]

This is coming along really well Pete. I haven't been on the GSR much lately, but I'll have to read the details over there as well.

Cheers Rich! Everything over there is pretty much copy/paste to here, so not missing much except some other guy's replies really...


I'm so keen to get this done because the Acewell sits just a little too far to the right for my liking.


And for tonight's work:



I got the mount for the voltage monitor aligned properly with the hole tonight and sanded the bottom bracket down to start preparing for the etch primer:





The mount looks a bit twisted and ugly now but it does the trick nicely.


I also got the JB Weld done to fill the gaps between the bent down sides and also to fill a couple of low spots:








I'll let that cure overnight and hopefully tomorrow night I'll be able to sand it back and maybe even get the etch primer done depending on the weather. They're predicting a possible shower or two so it may or may not be good painting weather.


I also made the most of having two multimeters at my disposal and compared the voltage at the battery with the voltage on the switched output from the ignition switch.


I'm dropping less than 0.3v through the ignition switch, so I should be safe to use that as the source for the voltage monitor. It's not perfect by any means but should do the trick.

[peteGS]

Got it in etch primer tonight!


Firstly though, I was thinking about the voltage monitor and how I wasn't real happy about it being out by the 0.3v I'm losing through the ignition switch, so I ducked out and picked up a horn relay today so I can have it measuring direct from the battery via the line running to the clock in the Acewell.





Tonight I got the cover all sanded back ready for primer:








Set up the drop sheet out the back and got them hung up and cleaned up with some wax and grease remover:








Then got two coats of etch primer on:





I think I got some runs because I was trying to get into the fiddly bits around the voltage monitor mount, so I expect I'll need to do a little bit of light sanding before spraying the black on.


So, while they started to cure, I had some thoughts on how to wire things up in the dash. I need to get switched 12v to the voltage monitor and the gear position sensor, and I need to connect the momentary switch to the voltage monitor so I can flip it over to battery monitor mode.


The relay mentioned earlier will sort out the switched 12v issue, but I needed some terminals to plug onto the provided pins on the voltage monitor that puts it into battery monitor mode.


So, I ripped my computer case off and found some unused terminals in there, so I cut them off to use for this:





I took the plastic enclosures off as I'll heat shrink them once I've got them connected to the switch, and here's where they connect to the voltage monitor:





Then I threaded the voltage monitor wires down through the gear position sensor sheathing to give me an easy way of getting it down to the end of the Acewell harness:





And, finally, here's the wiring diagram for it all:





If all goes to plan I should be able to spray the black tomorrow night which means it should be right to mount up maybe Sunday night, can't wait!