'81 GN400 (again)

Madmannc

Active Member
Hey guys, been on here a lot, getting ideas and sharing the progress (or lack thereof) of my old GN. I had my progress posted in the bob/section for a while. Anyways, I got it over a year ago on the cheap, got it running, learned to ride...then came the crappy and ill-conceived "mods" that made me think I was doing something. Here she was after all that mess:


But it was cool, it worked, it was different for the time, and I had a blast tinkering and riding.

And then it rained. A lot. More than average here in wilmywood in the past six or so months, and since I have no garage or storage, my bike has withered away outside, developing a lot of corrosion and rot from my noob mods. That and the fact that I didn't have health insurance and didn't feel comfortable riding without it, I decided to strip her down this winter and finally give it some much deserved love.


Breaking her down:


I have been a HUGE fan of Cierracarts GN400 build and sought to borrow heavily from that.

Painted the frame in bedliner. A pretty durable and inexpensive way to upgrade from what I've read.


Engine cleaned, painted and sanded the CH fins for that look..


And finally the rebuild has begun.


And that's where I'm at. So obviously this rebuild is largely in the cosmetic realm, but It really had to be done. There was so much pitting and rust and flaking paint and all that you would expect from an old bike. But I'll be getting a new taillight, fab a new seat, sealed battery, brake pads, and a couple other things, but mainly general maintenance.

Next are the forks and the wiring.

As far as the seat goes: I'm done with the cowl. I plan on doing a fiberglass seat pan and making a bonne-style flat seat that not only provides more cushion than a brat seat, but raises me up a bit. Hopefully the higher, more cushioned seat will also help with the "dog dragging its ass around" look that I've been told the bike has.

Sooo there I am; feel free to pick me apart :)
 
Sounds like in a year, you got an old bike running and learned how to ride. That's an accomplishment to be proud of, most people will never do either in their lifetime.

As far as the cosmetic changes go, I'm with you on that. After all the work, no sense having rusty bolts and an ugly seat. Not sure about bed liner for the frame but keep us posted on how it holds up. What did you spray motor with? I'm not a fan of exhaust wrap but to each their own.
 
Thanks for the kind words! I used Duplicolor high-temp Engine ceramic paint. Went on great! Real clean. Then I used a luthiers file to sand the fins. I'm interested to see how well the paint works when she heats up.
 
We've had some decent weather days lately (and then more friggin rain, now its cold), so I was able to get a little work done...





Got the outer tubes painted and the forks put back on, triple tree and handlebars painted, back wheel painted and put back on. Also got a new axle-mount side taillight and the wiring harness back in there...temperature should be in the 60's next week so I can fab a fiberglass seat pan.
 
Its been nicer-than-average weather, but still could hardly get things done. Workload (I'm a luthier) and then the wife got a bug up her ass to do all this remodeling...

Fix the leaking window.....yes dear.
Put up wainscoting in the kitchen....yes dear
move the fridge.....yes dear
rip out and replace the flooring in the bathroom....yes dear
install a new back door....yes dear

but I digress

Got a bunch of parts in the mail (vinyl piping for the seat, new drive chain, new brake pads, etc)
Had a little free time happen to I put a hoop on and did a quick fab of a battery compartment for this little sealed battery that other people have had some success using.



There are a few nice days left (before it rains....again) so I hope to finally do the fiberglass seat pan. I hope.
 
No go.

First of all, looks like you butt welded it. Sure hope you sleeved it. You also nearly ground the entire weld away. That is not strong enough, period.

It also does not look to have enough clearance for full suspension travel. That part is debatable from the angle i see.
 
Some indoor progress.

Managed to putty up a couple small badge leaks and paint the tank. Put some stripe on it as well, a shit ton of clearcoats...let it dry and will wetsand in the morning

 
DohcBikes said:
No go.

First of all, looks like you butt welded it. Sure hope you sleeved it. You also nearly ground the entire weld away. That is not strong enough, period.

It also does not look to have enough clearance for full suspension travel. That part is debatable from the angle i see.

Inserts were used. The clearance I think will be fine; I've seen worse on some bikes on here.
 
Still not strong enough with those ground welds. If you didn't plug weld it, you should. There's a lot of force applied in that area. Cosmetically it's a mess, but that's your prerogative.
 
Seeing a worst example than yours does not mean that yours is done the right way

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okay unless your 6 foot 6 the only force applied there is the weight of a seat or the rear hump because you shouldn't be sitting that far back. plus the shock mounts are gusseted to the main frame not to the hoop that you added. but that being said the hoop will hit the rear tire if you ever take the wife for a ride. ;D
 
tccook said:
okay unless your 6 foot 6 the only force applied there is the weight of a seat or the rear hump because you shouldn't be sitting that far back. plus the shock mounts are gusseted to the main frame not to the hoop that you added. but that being said the hoop will hit the rear tire if you ever take the wife for a ride. ;D

"there's no way in hell I'm getting on that damn thing with you."
-My Wife
 
Madmannc said:
"there's no way in hell I'm getting on that damn thing with you."
-My Wife

b2a47c96a14e172b8df940c8f25b7c96.jpg


Haha mine rode with me once. One and done !


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Some progress made....front tire on, fabbed a fiberglass seat pan and stitched a cover, turn signals back on along with other misc electrical and such, rear brake back on...still a lot of work to go but there is now and end in sight. Changed the angle of the hoop for more tire clearance, gotta sandblast the rear fender and paint it (front fender too).

Not really happy with how my seat came out. Wifes sewing machine shit the bed so I had to handstitch the rest. Had to use rivets for attaching to the seat pan. A little wrinkly, but it works for now. And it's 100% homemade.





 
Surely if you had a rear mudguard on it you wouldn't need to worry about health insurance cos nothing would be getting flung at the back of your head at 110 feet per second?
Nice project bike.
 
Erskine said:
Surely if you had a rear mudguard on it you wouldn't need to worry about health insurance cos nothing would be getting flung at the back of your head at 110 feet per second?
Nice project bike.

Fenders will be used. They're just not ready yet.
 
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