GS675RM (Retro-Mod)

[PlayerB]

Hi all,

Been lurking for quite a while. I picked up a 1981 gs550l for free from a coworker who wanted it gone a little over a year ago. It's been slow progress as I was still finishing my first build (BMW R80). If anybody is interested, I have a build thread on advrider's airhead section: http://www.advrider.com/forums/showthread.php?t=780462

That project is officially "finished" (They're never really finished though) and I'm finally full speed ahead on the Suzuki. Now that I've gotten enough done to look like real progress I wanted to start sharing my build. I'll also be posting these updates to thegsresources forums, but since I frequent both sites I'll be keeping this one updated along with it.

Here's what she looked like when I got her home.

Did some work on the carbs, replaced the battery, and got her to start up and run before i started the tear down.

My goal in this is full blown Resto Mod. Something in the Style of AC Sanctuary, Bull Dock, etc. Using the 1978 GS550e lines as the basis, updating the styling, components, and performance to bring this gal up to the modern day.

Calling her a GS675RM. Did some easy Ipad photo editing to get an idea of what I'm shooting for.

So far I've completed the following:
- swapped in a 2007 gsxr600 front end
- coginito moto triple tree drilled for a protaper bar and installed
- L tank and body work replaced for 1978 gs550e components.
- Frame modified to accept tank and body work
- Modified Seat Pan and shaped foam. Needs upholstry
- Mocked up Side covers. I'm planning on making these out of fiberglass.
- Mocked up rear shocks to get the rake/trail/stance that i want.
- Bracket made to mount gs550e tail light


There are going to be tons of other little things, but here are a couple of the other big ticket items:
- GS650 top end swap. I already have the top end components. Going to start tearing down the 550 engine soon to start the swap. Planning on a full tear down so i can properly clean the engine and give it a fresh coat of ceramic paint.
- Updating to 17" front and rear spoked wheels. Already have a gs1000 rear hub which should work with only a bearing swap. I'll be purchasing a cognito moto front hub for the front wheel.
- Full rewire. Leaning towards a Motogadget M-unit.

On to some pictures of where the build currently stands.

and just for fun, here's two of my bmw

 

[PlayerB]

well, unfortunately I haven't been able to do a whole lot on the bike this week. At least I was able to finish up the bracket for the tail light and license plate and get them mounted up. Planning on getting the headlight mounts, turn signal mounts, and steering stops finished before I start on the engine mods.

 

[coyote13]

That tail is MUY BUENO amigo

 

[PlayerB]

pulled some pictures of what I needed to do to make the E tank fit the L frame.

Rear bracket cut up and bent out of a piece of angle iron. Welded a nut to the back side. The tank rests solidly on the back rubber.

Front brackets were cut off, still need to grind everything down smooth. There's a hole already in place in the L Frame slightly forward and down. Just used a piece of threaded rod, a couple nuts and washers. Took the dremel to the front rubbers and they fit snugly in place. (sorry for the dark pictures...)

Overall, turned out to be a pretty easy modification. Bonus that the front hole, and support rubber in the back made the tank parallel to the lines of the subframe without any other changes. I can't stand the weird broken spine look these had off the manufacturing line; different lines between the tank, seat, and cowl

 

[PlayerB]

Slow progress, Had to set the zook aside for a little bit while the bmw needed some attention.

Turn signal, head light, and tail light mounts finished up.

 

[PlayerB]

Finished detabbing the frame. Next up, adding new brackets for side covers and electronics tray.

The back here will be hidden under the cowl. Just welded it closed and cleaned off the ends. You can see the new tabs for the rear turn signals as well.

 

[BigSherm]

Nice work!
That frame looks great, the lines of it remind me of a classic race bike.

Keep it up!

Sherm

 

[hooligan998]

I'm in. Sweet build so far!

 

[PlayerB]

Frame has been "re-tabbed" Added in mounts for the side covers, electronics tray, rearsets, and one for the rear brake reservoir. Cleaned off about 90% of the old paint off the frame. Going to clean up the rest as best I can before repainting. A lot of it came off a little too easy, so I wanted to make sure I have a good surface to bond to when I paint the frame. All the metal looked good underneath. No rust showing anywhere.

I designed some pieces to be able to mount on a pair of GSXR Rearsets. Those, along as the steering stop should be arriving from the machine shop tomorrow. Excited to get them mounted up.

This is one of the Rearset Mounts. It will also act as a spacer for the Swingarm Axle. Just like the stock units do.

Here's a shot of the additional bracket I added to the frame to support everything

Not a huge fan of blending welds, but I needed to make sure I had a flat surface to mount up to. I think there is plenty of weld around the backside to support everything

And the Steering Stop. This is going to bolt up to the upper triple tree and also act as a dustcover for the upper bearing.

 

[BigSherm]

Nice work, keep it up!

 

[PlayerB]

Did a final dry fit of everything before I paint the frame. Lots of pictures coming up.

Steering Stop bolted on to the upper triple tree

This one is looking up. You can see the tab that was already on the frame that I'm using as the positive stop

From the front with the bars turned all the way

Looking up with the bars almost at full lock

 

[PlayerB]

Rearsets and spacers

And a couple of the whole bike

At 6'3" 220lbs I make her look a little small. But I think I got the stance and seating position right. Feels good.

 

[canyoncarver]

I really dig where you are going with this. Nice work.

 

[PlayerB]

First coat of paint down on the frame.

Using this stuff

Used it on the BMW and I'm a big fan. Any touch up needed blends seamlessly with the original coats. I'll flip it over in a week after its fully cured and lay another coat down and make sure I have 100% coverage. I have put multiple coats down quicker than suggested by the can before, but it is easy to screw it up. If you lay down too much too fast, the solvent (or whatever else is mixed in with the paint) will attack the original layer if it isn't fully cured and it will start to bubble. In the meantime I will start laying down some paint on the other parts that need it.

 

[Beau]

That's going to look real good. Keep it up!