Re: GS550E 1980 w/ 673 top end swap [aluminum swingarm swap completed]

[jwegman]

I figured I would share my build from the gs resources here as I venture into more customization. This is a build that I bought in march and got on the road by August. Since then I have been upgrading more parts and have big plans for this winter.
Current Status:

And the story goes:

I bought it off craigslist in early march, the guy was cool enough to drive it over to me. 1980 GS 550E:

These past months were spent taking a ton of stuff off the bike, researching info here, designing the build and ordering parts. I'm going for a modern cafe look.

My slew of parts:

mac 4-1 head pipe, pirelli sport demon front tire, K&N pods, hella horns, Custom LED taillight, turn signals, grips, clip-ons, headlight brackets, clutch lever, mirror, gaiters, acewell gauge, and shorai battery.
not yet received: muffler and MC from DCC

 

[jwegman]

Re: GS 550E 1980 -cafe build

From: May 22

Update: last week I cleaned the forks to a dull shine. I started with 220 grit and worked my way up to 800 for the brushed finish I wanted.

Broken down as far I will go for now.


Did some grinding on the frame:

I removed excess tabs and passenger pegs and supports. I am removing the center stand as well. I want to be able to have the option to carry a passenger. When I make rearsets over winter I'll include something.

I mocked up the left side bars.


The first run of the bridgeport after I rebuilt it (bought from a foundry where they left it outside for a year) It still needs more tooling and fixtures, final setup and digital readouts. I drilled up a bracket for my ignition and choke cable relocation.


This will sit under the seat, I could not stand having the choke on top of the triple tree.

And a quick placement of items to see how she looks.

 

[jwegman]

Re: GS 550E 1980 -cafe build

From June 9th:

I finished the grinding and smoothing for the frame. For the frame ends at the back of the seat I cut a wedge out and then bent and welded them closed.


back of the frame ready for paint. I would like to eventually powder-coat the frame but this will do for this season. Don't mind the chain, I need to buy a chain break and probably a new chain.


Here I am attempting to make a spacer for the speedo delete on the wheel. I ended up messing it up just before I was done. Instead I ended up throwing the old one in the bridgeport, milling away all the housing material so I could then put that in the lathe. It ended up working well but was way more work and time then I wanted for a spacer.


I put the new bearings in the wheels and threw the discs on. After I mounted them I realized that I have them reversed. I originally had them right too, but for some reason switched them after they didn't go on easily.








You can also see I made some turn signal brackets. The powder-coated headlight trim ring, painted bucket, and powder-coated top tree look great on the bike. The shocks were painted real quick, I plan on upgrading to nice gas shocks in the fall, but they are not in my budget for now and I don't want to waste my money on cheap ebay ones.

Upcoming this week will be the finishing of my electrical panel. I have got everything figured out and made up, it just needs to be wired.

Also this week I want to mount the taillight and get foam on the seat (if for nothing else just to make it not look like a terribly done brat).

 

[jwegman]

Re: GS 550E 1980 -cafe build

From June 12th:

I haven't done anything on the bike over the last few days. I was busy taking the msf course and passed, now just to finish the bike. I did however take some more pictures of stuff that was previously completed.

Here is a better picture to show how the wheels turned out.


I painted the headlight bucket and the chrome ring was powder-coated, and installed with chrome hardware.
You can also see the nice top tree.


Another showing the top tree.


Electrical panel made from 2 pieces of poly-carbonate bent and riveted together. This holds the battery, new fuse block, igniter, turn signal relay. To the bottom of this is mounted the r/r offset with spacers for heat dissipation. The ignition and choke are also relocated on a bracket underneath. The starter relay will be under mounted as well.

 

[jwegman]

Re: GS 550E 1980 -cafe build

From June 14th:


Today I finished making the rest of the brackets I need, this includes a hazard switch bracket, horn bracket and taillight bracket.

This is the horn bracket.




I even got it installed. These are horns that a lot of the Subaru rally guys use, they should be really loud and piercing at 118 db.


In this picture you can also see the tachometer delete plug.


I also started work on the tank. Before:


Mark the area to dent on paper then cut out 2 copies and tape to each side.


you can remove the paper after you get a good outline.




Here it is mounted and partially stripped. I've got a bit more smoothing to do and I need to go deeper on the right side but it's starting to look like a cafe racer. I may need to do bar dents too.

 

[jwegman]

Re: GS 550E 1980 -cafe build

From July 19th:

Big updates: I've made a lot of progress over the last month, although not as much as I would have liked, my budget went over and I had to put in extra hours to get money to finish the build.

I finished cleaning the engine up and installed the headers and slipped on the muffler. This is going to be loud (may need a baffle).

Installed new chain.

Made and installed new cables. What a pain this turned out to be. I ended up losing the little plastic bushing thing on the end of the clutch barrel. It flew off while I was trimming the cable and went somewhere in my garage. I spent 2 hours looking for it with no luck, also can't seem to find one online.

Finished the electrical:
Wire nutted everything together for a test. Worked with just a few issues I had to chase. Wired in for coil relay and horn relay mods.

the taillight is super bright and the horns super loud.

Cleaned everything up, shortening where necessary and installed a few new connectors.

note: still have to wire in turn signals (broke one while mounting) and wire in license plate lights once I figure out a mount.


Rebuilt the carbs:
When I bought the bike the p.o. said it was't running properly and had trouble at low idle.

Opened them up to find 3 broken float posts JB welded together...
Luckily with the bike came a box full of a disassembled set of carbs and spare parts. The disassembled carbs were good except for one post. I was able to make a full set with only one nicked post (just above hole was sheared off).

box of parts that saved me:

I may end up building a second set of carbs to sell once I repair all the posts.

Also upon disassembly there was a missing washer on the main jet, I'm assuming this was what was the cause of the trouble.

The parts got the dip and o-ring treatment, new larger jets, and I'm just waiting on pilot jet plugs.

I cut foam for the seat.

I'm in the process of making a fiberglass cafe seat bubble. This will be removable so that the seat can hold two people.

I cut up an old polystyrene cooler and glued it together. I shaped it with a bread knife and 36 grit sandpaper. This makes a huge mess.

Once I had the shape I wanted covered it in tape it and waxed it.

I've got one coat of fiberglass and epoxy and its already pretty strong, I plan doing three total.

The bike should be finished early next week!

 

[jwegman]

Re: GS 550E 1980 -cafe build

From August 5th:

Here she is. The paint was such a headache, I'll update later with the process and issues encountered. All that's left for now is upholstery, which will probably have to wait a few weeks.

 

[jwegman]

Re: GS 550E 1980 -cafe build

Post From October 11th:


Pictures of paint process and recent updates

Primered

White on

Here is where things started to go wrong...
Taped off for some stripes

One of the colors

Less than thrilled at the outcome, I like the colors but the spacing is all messed up.

Restart

Cleared without stripes

Another picture all finished

Went to the Rochester Distinguished Gentlemen's Ride. We got rained out but still had a blast.They had two camera vehicles, still waiting on video.

Even came home with a trophy: Best Bike

 

[jwegman]

Re: GS 550E 1980 -cafe build

This is the last post from the past, from this point on I bought an '83 gs650g without a title and will swap the top end of the motors, and swap the forks giving me dual discs with more options for upgrades. I also plan on purchasing DCC rear-sets and mounting them to '86 interceptor brackets that have passenger pegs. I also need to upholster the seat.


Post from October 11th:

Last week I hit a large pothole. My rear shocks didn't decompress afterwards.
The bike was low enough that my solid mounted license plate was scraping on the chain. They measured 11" instead of 13"

I decided to replace with higher quality, no more pogo sticks.
I went with 360mm ~14.25" significantly longer than stock.
It was a long week of waiting but they finally came today.

Here they are next to the compressed shocks!

Fitted

Look at that stance.

Took it out for a ride and it is a whole new bike. Bumps don't want to buck me off like before, it feels so much sportier in the corners as well.

Issues: I still have to get used to putting my feet down further. It leans over on the kickstand much more, I'm thinking of bending it out?
Chain is a bit looser that I like, at times it rubs on the swing-arm. I may have to get a tensioner or a plastic wear guard.

 

[jwegman]

Re: GS 550E 1980 -cafe build

With winter in full swing here and a break from classes I have begun to dig into phase II.

rearsets: I purchased some '86 interceptor brackets.

I browsed forever trying to find a suitable bracket, one that would match the slope of my frame, look good, and have passenger foot pegs. I plan on drilling the front peg and mounting DCC universal rearsets to these. I still have to buy one side as I encountered a scummy ebay seller. I also need to fab a steel bracket and weld it to the frame.

I also came across this ' 83650g on craigslist around thanksgiving.

No title, and cheap. I have already sold the seat and recovered half my purchase price!
Now I can join in on the recently popular 673 top end swap.

Started the tear down.


Got the motor out 2 days ago. I never realized how heavy they are, made me realize that we are basically riding around on an engine with wheels on it.


From here I need to take the motor apart and see what shape it's in before I tear out the 550.

I would also like to use the forks from the 650g so I can use the dual discs (eventually do a twin pot upgrade). I am not sure if there are differences between the 650e and 650g forks. I don't want to put on lesser components just because I have them, I would rather wait and buy 650 or 750e forks if necessary.

As for the 650g I haven't had much interest in other parts from it. It's not really in great enough shape to do a quick spruce and sell. I'm currently toying around with the idea of putting the 550 block on it if it's possible. Maybe doing a scrambler style build, not that I need another project/moneypit...

 

[Big R]

Re: GS 550E 1980 -cafe build

Yep, I'm digging this. I never saw this on the GSResources ......

 

[danejurrous]

Re: GS 550E 1980 -cafe build

Rich I think we have a similar interest although I am not sure what it is yet...

Nice looking scoot!

 

[Toast]

Re: GS 550E 1980 -cafe build

The bike is looking great, I like the wheel color. How comfy is the seat?

 

[gk45011]

Re: GS 550E 1980 -cafe build

I'm late to the game. I gotta start browsing more..LOL

i'm on board. Nice to see a lot more GS popping up on here.

GK

 

[LovingtheCLE]

Re: GS 550E 1980 -cafe build

Excellent stuff! I love what you did with the 550e and can't wait to see what you do with the 650 shaftie!

I love the removable cowl! This is a must for my 650G build. My wife loves to ride. How can I resist keeping it possible to have a gorgeous woman on the back of my bike as often as possible?

 

[edukaycheon]

Re: GS 550E 1980 -cafe build

Excellent stuff! I love what you did with the 550e and can't wait to see what you do with the 650 shaftie!

I love the removable cowl! This is a must for my 650G build. My wife loves to ride. How can I resist keeping it possible to have a gorgeous woman on the back of my bike as often as possible?

I agree, the removable cowl is cool. I'm going to have to figure out how to do this with my bike

 

[jwegman]

GS 550/673 E 1980 -cafe build

I've made a bit more progress on the build since last time. Not a lot of physical work but lots of researching and part finding.

Finished tearing the 650 down

Nothing but a frame a box of parts, wheels and motor.

Parts from the 650 that I will be using on the build.
Carbs: These are in great shape so I'll refurb. them and get a dynojet kit.
Forks: I want to use the lowers so I can go dual disc but I'm having trouble finding a diagram to take them apart specifically the top.

Everything I need from the motor. Very minimal carbon deposits too.

Leftover bottom:

Wrestled the 550 out:

I'm still figuring out gaskets, ignition and cams on the motor. I want to run the 550 cams in the 650 head but don't know how this works with the bearings.

 

[NBraun]

Re: GS 550E 1980 -cafe build

Awesome dude, diggin the white. Builds great!

 

[jwegman]

Re: GS 550E 1980 -cafe build

I managed to get the 650 forks all apart, there was a ring in the top that couldn't be seen or removed unless you push down on the recessed top cap.

Also got my Dime City Cycles order in. Rear sets, linkage, and passenger pegs.

Had to modify the bracket a bit to hold the pas. peg but got one mocked up.

Also got my mikesxs cartridge emulators.

Just have to get the 550 forks apart and figure out what to do for springs.

 

[Toast]

Re: GS 550E 1980 -cafe build

Awesome, I've only heard good things about cartridge emulators. Btw I would go with a straight rate spring from Sonic or Race tech, especially with the emulators. When my bike was up, it was still very comfy with the stiff sonic fork springs that I installed and handled amazing.