gs550 carbon cafe racer

[carbon moto]

This will be this years show bike, hopefully ready around April time.
its a 1979 Suzuki gs550 barn find with only 11k miles on it
spent a couple of hours on it to reduce it to parts, we will only be using the frame so if anybody needs any parts i have plenty going cheap

spent a few hours today (most of the morning actually) removing all the brackets from the frame, cut out the lower frame rail, the one the main stand bolts to - did this as i am going to open the frame rails 20mm to fit the new swinging arm.
Once i got going with the grinder i decided to do a bit of bracing as i will be upping the power by a lot (gsxr750 r705 engine as i have 3 or 4 kicking around)

i just tack welded the braces as my mate is a pro welder so i will let him do the welds properly.will be test fitting the engine tomorrow with the exhaust so i can work out where the cross braces will go under the headstock to the brace just above the front engine mounts
will post updates as i go
please feel free to advise me as i work with composites for my living & am not a pro bike builder so any help will be welcome
tony

 

[john83]

These builds involving a classic frame and a modern engine are always fun to watch.

 

[carbon moto]

managed to get the engine in yesterday, phew it ws a tight fit
had to take the rocker cover off & remove the sump bolt so it would go in.
the rear upper engine mount lines up ok will have to make brackets up for the rest to line up.
Suzuki use the same head bearings throughout most of the range so got to fit some gsxr750 m yokes for the upside down front end.
more pictures next week

 

[stroker crazy]

I'm signing up for this build!

Crazy

 

[mokie]

Looks like a build worth following!

 

[carbon moto]

Had a very busy week at work this week sending carbon parts to the Usa,New Zealand, Italy along with a couple of wholesale orders & our Uk customers so not had much time to work on this project but still got a few bits done.
Here is what i have done this week,the engine is roughly in, needs mounting brackets making, have had to mount from the front bolts instead of the rear to pull the engine forward to clear the air filters on the frame rails.
The exhaust is loosely fitted to check for clearance for the extra bracing under the head stock to the new cross member i fitted last week.
Swinging arm now fits the frame (roughly) its a honda bros arm which i have fitted a vfr750 L hub & caliper which allows me to use a vfr 5.5" rear wheel, 180 section tyre.
The swinging arm mounts on the frame needs drilling out from 15mm to 16mm to fit a bros spindle & a center mount & it will need bracing possibly to the lower frame brace & engine mount which i have to make 20mm longer than standard .
The next major task is to widen the frame at the left swinging arm mount by 15mm to allow the chain to clear & let it run true also this puts the arm slightly over & the rear wheel bang in the center of the frame.
The forks are gsx750/1100 L & the wheel is the same at the moment, that will change for a honda wheel to match the rear prob an early 16" fireblade with speedo drive.
Tank cover is a rickman cr long tank unit which i have started to smooth ready to make a mould from
Next week i have to make rear shock mounts, rear set, mounts coil & battery box mount & try to finish the frame ready for blasting

 

[Bert Jan]

When you say you've got a mate who's pro welder and youself being a pro carbon/composite dude, I can't wait for updates!!

Will be one sick bike!

 

[carbon moto]

When you say you've got a mate who's pro welder and youself being a pro carbon/composite dude, I can't wait for updates!!

Will be one sick bike!

Did i mention i was also a pro painter specialising in custom paint jobs, (flake candy marble ect)
These days i try not to do to many as i dont get the time, mainly painting for a good finish before i make a mould & laquering the finished carbon products.
I do have a few ideas for the finish of the bike, will be simple but striking- keep watching

 

[joeybaggadonuts]

Definitely signed up!

 

[carbon moto]

have just added another 100 plus moulds to our collection, spent some time sorting that lot outl!!
just fitted the rear shock & started making the frame mountings up for it, will finish the bracing & hopefully get the frame welded up fully this week.
did a bit of work on making the plug / master for the seat unit mould, 7 layers of insulation foam bonded together with mastic & left under the weight of the bench sander for the weekend, have started to do a bit of shaping with a bread knife borrowed from home (please dont tell the mrs) have quite a bit to do on this but its taking shape slowly
tony

 

[JustinLonghorn]

Alright, I am on board.

 

[carbon moto]

just a quick update
got the shock in & mounts tack welded, have made it so i can adjust the ride hight with shims if needed,
also got the bracing done around the swinging arm spindle & from the headstock to the new cross member at the front of the frame, the rear wheel is now central in the frame & the new lower frame cross member is ready to be fitted when i remove the engine (again)
next week will hopefully get all the engine mounts mad & engine fitted properly
forgot my camera yesterday so will take photos & post them monday
tony

 

[dp9]

siiiiiiiiick.

that engine looks monstrous in that frame.

i'd love to see some shots of the frame mods for the swing arm swap. i think i can understand what you were saying but pics are worth...

 

[carbon moto]

not much happened here as im very busy actually working
my mate took the frame last week to weld up properly will put pictures on when it returns
have now got an early blade 16" wheel in the front to match the rear
with speedo drive,
will hopefully make spacers up to centralise it & caliper mounting brackets in the next few days
tony

 

[Ringo]

If I may hijack for a second...I'm making some carbon parts using epoxy resin, and I'm wondering if I could get our opinion on how best to clear them. I was considering clear gel coat, but epoxy and polyester don't play well together, right? Maybe just a standard urethane clear? Thanks in advance for any insight!

 

[Rusnak_322]

Ringo - I clear coated factory carbon fiber parts on my Aprilia and they looked great. The clear also can fill in some small pinholes that form on carbon fiber. Just lightly skuff the part and spray like normal.

If you have not made the part, you can get some clear resin (not sue if it is epoxy or poly). There are tons of how to's out there for overlays from all the Honda civic owners doing up their parts.

If it were me and it wasn't a race bike where every oz mattered, I would make the part in fiberglass and do the overlay. That way you can get the part 100% in glass and not worry about cosmetics when you are initially fabbing it up.

 

[carbon moto]

If I may hijack for a second...I'm making some carbon parts using epoxy resin, and I'm wondering if I could get our opinion on how best to clear them. I was considering clear gel coat, but epoxy and polyester don't play well together, right? Maybe just a standard urethane clear? Thanks in advance for any insight!

it depends how you are making them
if you are vac bagging or infusing dont bother with a clear coat
if you are wet laying up use an epoxy clear coat let it go off (still tacky but doesnt leave any residue on your finger when touched)
then lay up as normal
hope this helps
tony

 

[Ringo]

Yes, it will be a wet lay up. So you're saying basically throw down a layer of resin, then continue as normal? And this outside layer can be sanded and buffed...or sanded and cleared? Thanks mate.

 

[carbon moto]

Ringo - I clear coated factory carbon fiber parts on my Aprilia and they looked great. The clear also can fill in some small pinholes that form on carbon fiber. Just lightly skuff the part and spray like normal.

If you have not made the part, you can get some clear resin (not sue if it is epoxy or poly). There are tons of how to's out there for overlays from all the Honda civic owners doing up their parts.

If it were me and it wasn't a race bike where every oz mattered, I would make the part in fiberglass and do the overlay. That way you can get the part 100% in glass and not worry about cosmetics when you are initially fabbing it up.

i think he is talking about making a part from scratch not an overlay (may be wrong)
why make the part in fibreglass then overlay it when its easier to lay the carbon in the mould then back with fibreglass using epoxy resin (could even use polyester if only 1 layer of carbon is used)
either way the finish can be enhanced with a couple of coats of 2 pack lacquer
tony

 

[carbon moto]

Yes, it will be a wet lay up. So you're saying basically throw down a layer of resin, then continue as normal? And this outside layer can be sanded and buffed...or sanded and cleared? Thanks mate.

yes thats correct or you can get an epoxy gel coat (clear) it holds to the sides of the mould better than standard epoxy resin
sand buff or lacquer as normal - leave for a couple of days or more to fully cure especially when its cold
tony