'81 Suzuki GS450 Cafe Build. An Odyssey

Made a little progress today, but kept it short because it's a bit rainy and cold.
Got some unnecessary tabs ground off of the frame and made my molds for my removable fiberglass cowl and my side covers. This planters foam was a dream to work with. I molded it small to give me enough leeway to build the fiberglass out beyond the pan so that I can sand it flush. Decided to make my side cover molds out of the same foam, as the top corners will have to bend in a bit with my frame.
 

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I'm still trying to determine how I want to fasten the cowl to the seat pan, whilst having the option to remove it with ease. The fiberglass will be roughly 1/4" thick, and will just sit right on top of the seat pan. I'll be padding the top, so that the rest of the pan is exposed, so I don't have many options as far as a base goes. Thinking about trying to fasten a thin pin into the fiberglass that just inserts into the pan. But we'll see.
 
Nice! I am on the same boat on mounting options. see my thread for my progress and mounting Idea.
 
That black engine is so sick!! Can you just paint your spark plugs like that without it being a problem? Now that I look at it the whole engine looks awesome, the crank case and what not look so clean!! Did you powder coat the engine or just high temp rattle can it?

The mounting fiasco is definitely something I don't understand, do you just bolt down the fiber board to the two frame or is their more of an ingenious way to put it on?
 
Thanks! I'm happy with how it turned out. The plugs are going to have to be replaced. They had some corrosion on them anyway. I just find it's more efficient than stuffing paper towels down there. I just used a rustoleum engine enamel (low gloss black and cast aluminum)

As for the seat, I mounted an aluminum bracket to the underside and used the raised cross bracket from my frame, which I chopped the center out of, bent downward, and drilled holes into to bolt the pan on. Looks a lot cleaner without the stock mounting holes that I cut off of the back of the frame. I'm putting the seat on hold until I start getting everything put back together. I've got parts lying all over the place and it's a bit overwhelming. Hope to start fiberglassing once I get my front end back on.
 
What did you use to clean your engine (assuming it was dirty at first) before you cleaned it? Did you just take it off the frame and spray paint it? I am a noob and just assume that spraying the engine with spray paint is a bad idea, but as long as it doesn't get into the spark plug holes and the exhaust ports not much can go wrong eh?

I think I would need to see close up pictures to really under what you did! You fiber glassing it yourself?
 
As long as you get a high temp engine enamel, the rattle can can be a good, cost effective alternative, as long as it's prepped well. I stripped the former paint on it with a spray on paint stripper and found that my cases were scratched and scuffed pretty badly, so polishing was out of the question. I spent about 2 hours scrubbing it with a wire brush and some simple green degreaser. It was a little tedious, but necessary to be sure there is no pealing or bubbling (oil paints don't adhere well to grease and oil)

I'm going to be fiberglassing a removable seat cowl and side covers. Hopefully it works on the first try ;D
 
Awesome! I was wondering what you used to clean it, but sounds like I am going to be taking a wire brush with some simple green to my engine and cases and just go to town! Sorry to be repetitive, but did you take your engine and cases off your frame or just spray it attached to the frame, looks like you did cause the frame had some silver spray.

Overall super stoked to see your build!!

I had a question about what I think are air filters...

So here are yours:

Bike.png


And here is my huge clunky airbox... can I get rid of my airbox and throw on nice little air filters like yours?

bike2.png
 
I wasn't ambitious enough to do an engine pull just to paint, and since I'm doing the frame I figured it wouldn't hurt to just mask the crap out of it.
And those are just pod filters. 48mm. You can pick up a pair on ebay for about $20. Looks MUCH cleaner than that awful air box (which is a pain in the arse to get out! So good luck with that. I had 2 hands on it and still ended up tearing the thing apart getting it out.)

FYI- when you switch to pod filters you will want to re jet your carbs. I forget what size I went with, but I'll try to dig up my old purchase info and find out for you. You get a lot higher air intake with those filters, and if you try to run without new jets you won't have any power. I went a month without new jets running pod filters, and just wrapped electrical tape around the filters to restrict air flow. A little ghetto, but it did the trick. ;D

Have you started a thread for your GS?
 
barnabasantioch said:
I wasn't ambitious enough to do an engine pull just to paint, and since I'm doing the frame I figured it wouldn't hurt to just mask the crap out of it.
And those are just pod filters. 48mm. You can pick up a pair on ebay for about $20. Looks MUCH cleaner than that awful air box (which is a pain in the arse to get out! So good luck with that. I had 2 hands on it and still ended up tearing the thing apart getting it out.)

FYI- when you switch to pod filters you will want to re jet your carbs. I forget what size I went with, but I'll try to dig up my old purchase info and find out for you. You get a lot higher air intake with those filters, and if you try to run without new jets you won't have any power. I went a month without new jets running pod filters, and just wrapped electrical tape around the filters to restrict air flow. A little ghetto, but it did the trick. ;D

Have you started a thread for your GS?
Click to expand...

Yeah totally well that's good, your plans sound like something I want to do with mine, I def don't wanna pull the engine but I really want to make it look nice and clean I will go clean it up sometime with some simple green!

If you find out the info on your air filters then definitely hit me up with it, I will start lurking eBay for some 48mm ones. On GSResources people were saying it was terrible trying to rejet CV engines with air pods, they were all talking about it like it was the worst thing in the whole universe... I definitely hate how clunky the air box is, plus it's so ugly!

Hahahahha no way, that's hilarious, but sometimes ghetto works and there ain't nothing wrong with that!

I started a thread on GSResources, but I will duplicate over here on DTT right now too! BTW did you get both air pods for $20 or each for $20?

Here is my GSR thread: http://www.thegsresources.com/_forum/showthread.php?t=188143
 
This look similar to what you got?

http://www.ebay.com/itm/2x-SUZUKI-GS450-GSX400-E-GSX250-GS400-GS250-T-E-CLAMP-AIR-FILTER-POD-CHROME-48mm-/200669746280?pt=Motorcycles_Parts_Accessories&vxp=mtr&hash=item2eb8d95468#ht_3643wt_1270
 
The bike is looking sick. I'm so pumped to get my project started. Next week I'm gonna be ready to rock and will be using all you threads for most of my ideas. Btw I'm rocking a '83 GS450T. Hope to my mine look as sick as yours.
 
The Gs450 air box is a beast to get out. I think you are supposed to unbolt the motor and shift it forward in the frame just to get the air box out.

Either way, the bikes looking good man!
 
Big Rich said:
The Gs450 air box is a beast to get out. I think you are supposed to unbolt the motor and shift it forward in the frame just to get the air box out.
Click to expand...

I can't recall the finer details, but I got my GS airbox out without having to move the motor.

It came out in one piece, too ;)
 
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