82 GS450E Scrambler from Aus - Done!

[peteGS]

Thanks fellas! Got out for a test run today on my newly found test route. Got some nice curves and scenery all in suburbia not far from my house and totals about 36km


Anyway, doesn't look like any oil seeping out the valve cover so far and she ran just like she did before the service, so all seems good.


Did a compression test when I got back while she was still warm and about 135PSI in both cylinders so all appears to be good in that department too


Hanging for next weekend and hoping like hell the weather improves. We have the inaugural Brisbane and South East Queensland GSR run planned for the 5th of Feb but all it's done this week is rain and they're predicting more. Hope it clears before next Sunday...


I desperately need to give her a good clean and polish and the paint job is due for wax now too so that's gotta go on, and I still need to find some time to get the Colortune into action...

[peteGS]

I've started riding to work this week, and happy to report that so far there's still no sign of oil seepage from the valve cover 
 
However, it has highlighted how sick and tired I am of having to drag my tank bag everywhere just so I can have a set of tools handy... so it's about time I sorted out somewhere to put a toolkit on the bike.
 
I reckon here is just the right spot
 

 
Only catch if you look close is there's no solid bottom, gaps all around the bottom of the tail piece so everything will end up on the ground somewhere, so time to do more alu. work and make up a tray to bolt in there. I'm going to use the front bolt mounts of the tail light bracket and two of the rear guard bolts.
 
Did up a plan:
 

 
And got it drawn on the alu. sheet last night:


 
Not 100% certain how I'm going to do the rear bit where it will need to bend/fold around the front of the tail light bracket but the rest of it should be good to go.

[Big Rich]

Great idea Pete! Gotta commend you on going the aluminum route.......

I was looking on ADVRider and a guy over there got a Shorai battery - used all the extra space in his battery tray for a tool kit. Just an idea......

[peteGS]

Great idea Pete! Gotta commend you on going the aluminum route.......

I was looking on ADVRider and a guy over there got a Shorai battery - used all the extra space in his battery tray for a tool kit. Just an idea......

Cheers Rich! I'm glad I started working with the alu. a bit more... I'm finding it pretty easy to work with (better than steel) and far less messy than fibreglass. The only downside is not being able to weld it myself, but welding's a whole different ball game that I'm crap at anyway and I haven't had to do much at all so far...
 
Would love to get a Shorai but I just can't come at the price... good idea though!
 
And I did start cutting last night, but blunt hacksaw blades and sweating like a pig meant I didn't get too far. And to preempt the jigsaw suggestions... it's too noisy for 9pm at night in the garage 
 

 
The house mate is hopefully picking up new blades today so hopefully I can finish the cutting tonight and work out the rear bit where it needs to go over the tail light bracket.

[Rich Ard]

Tin snips if you've got 'em. If you don't, it looks like you could trade someone about twenty screwdrivers for one.

[interceptor]

Hey Pete,
Lookin good-very creative.  Can't wait to see how it turns out.

[peteGS]

Tin snips if you've got 'em. If you don't, it looks like you could trade someone about twenty screwdrivers for one.

I used tin snips on my very first attempt at the electrics tray with galvanised steel... it ended up in the bin because the snips I have bend thin metal as the cut... but yeah I s'pose there's a few screwdrivers there I could trade for a new set... hahahaha
 
Got it sorted though with new hacksaw blades

[peteGS]

Hey Pete,
Lookin good-very creative.  Can't wait to see how it turns out.

Thanks mate... getting close but had to cut it in half 
 
I'm trying to post progress pic's but Photobucket keeps telling me I've had an exception... I think that means it'll work for everyone except me 
 
I'll get some up later.
 
Basically I cut it out, worked out I couldn't wiggle it in place, so cut it in half down the centre so I could get each half in on an angle.
 
Then I worked out the front mounts will stop that, so got rid of them and bent the front up so it's a tray on all sides now and had to trim the front of the side back a bit as well.
 
So one side now goes in, but I need to cut down the bent up side a bit so it will go further back and to the side so the hole lines up with the tail light mount. So close!

[MILLENNIUM FALCON]

Just don't cut your fingers! Anytime I work with sheet metal I end up saying, "where is this red stuff coming from."

[teazer]

I hate that warm wet sticky feeling when I slash something open that isn't designed to be open - like fingers...

[peteGS]

Thanks fellas, so far this time it's just been a couple of nicks, no slash and bleed type stuff
 
And Photobucket has decided to start cooperating so here's the promised pic's, but no further progress yet:
 
Cut and bent:
 

 
No way can I get it in like that though, too wide to put in on the angle:
 

 
Drastic action required:
 

 
Got rid of the front mounts and bent the front up so it's now a proper tray:
 

 
And I'll be laying some rubber down like this which will both give some cushioning/stop rattling and form a hinge of sorts so I should be able to unbolt it, lift it in the centre, and take it out if need be:
 

 
Working with the right side only, still won't quite go in as I measured too low down in the A frame on the side:
 

 

 
Bit of adjustment at the front and it's almost there:
 

 
So, I need to fix the side, I think it needs to bend in further or be shortened and then it should go far enough back and to the right to be able to be mounted properly. Then I can replicate that on the left side, smooth all the sharp edges, glue the rubber on and call it done

[peteGS]

No more progress but a number of the local boys (and girls) on the GSR forum got out for the first Brissie/South East Qld GSR run yesterday... 350km's of awesomeness in 32 degree heat with 60 odd % humidity... had a blast! The 450 was flawless as opposed to the pilot, but I didn't get left behind too much by the big boys on the Katana's, 1100's, 1000's, and 850...

[interceptor]

I'm jealous.  Sounds like you had a good time!  Good job on the tool tray. 

[peteGS]

I'm jealous.  Sounds like you had a good time!  Good job on the tool tray.

Yeah mate it was awesome! My legs are still recovering but it was well worth it... just means I need to get out more
 
I'm hoping to get back onto the tool tray this week but had to work 10pm last night and again tonight...

[peteGS]

Still no progress on the tool tray but now I need to do some wrenching... stator's buggered 
 
Went to start her up for the trip to work on Thursday but wouldn't crank, so on the train to work dammit.
 
Turns out the stator's not putting enough AC voltage out, should be about 75VAC at 5K RPM's, but the three legs are 56/52/48VAC so that ain't gonna help.
 
Trickle charging overnight so I can keep riding her but hopefully can get a new one locally this week.