1981 GS450T street tracker, uk.

beachcomber

TJ - Beachcomber
DTT SUPPORTER
That's looking the bollox. In envy of your skills !

Love the use of alternative modern materials.
 

Dazzo

New Member
That's very kind of you to say beachcomber, thank you.
Getting the rest of the welding done tonight so that I can get the seat mounted in its final place, then I can get the forks and wheels off to start cleaning the frame up for paint.
The use of carbon may go a little further, started a front mudguard in carbon today but I'll need a fork brace of some kind as the original has a steel support welded under the chrome fender.
 

Dazzo

New Member
First application of resin on the carbon guard, it's got enough strength already so just a couple more layers so smooth it over and trim to fit, it's 130 grams vs chrome guard at 1.3kg.
 

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Dazzo

New Member
Seat hoops done at last!
I'm not sure if I want to plate the frame under the seat or not, it adds weight, I may try an undertray in carbon or something.
 

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Dazzo

New Member
Got a bit more done with the frame.
The tank originally had 2 rear mountings that fastened to a kind of bridge on the frame, ugly and a pain to work around, I also wanted to lower the back of the tank a little to line up with the seat unit better.
So, cut the bridge off, welded a new bar into the frame for a central fixing.
Then I had to make a piece to weld into the back of the tank.
 

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Dazzo

New Member
So, with that part done, I welded in a couple of steel cross pieces to mount the seat unit, welded in a few captive nuts, then got the seat unit lined up and drilled for the fixings.
I need to trim the front of the seat foam and re-staple it to its base as it needs to be a bit shorter but you get the idea.
 

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Dazzo

New Member
And made a start on the carbon undertray, this will also form the top of a carbon airbox, with short velocity stacks inside with a foam filter.
 

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Sotaro

New Member
I am enjoying your choice of motorcycle and your rapid progress. Also, the carbon fiber fenders are very nice. So many folks eschew fenders which I think is wildly shortsighted. How much time went into your fenders? My theory on fender construction is that the deeper the fender, the stronger. Any thoughts?
 

Dazzo

New Member
Thanks for your interest!
The fenders only took an hour or so, I just wrapped it around the original chrome one and brushed resin over it, baked on a low temperature for an hour or so.
It is very thin, but strong, I'll be using a fork brace for support anyway.
The original fender was 1.3kg, carbon one is just 128 grammes.
 

Dazzo

New Member
Small update, frames done and ready for paint!
Some of the 40yr old paint shows no sign of wanting to leave the party so it's been sanded and scotch brite cleaned.
Also managed to get the very stubborn bottom headstock bearing out, savage heat is your friend!
Also, an update on the carb front, decided on later GS500 carbs, bit more modern design, easier to set up and half the weight of the originals.
And K&N do a double filter for it at reasonable money.
Should be here by the weekend.
 

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Dazzo

New Member
Got the frame in etch primer for a bit of protection, it shows up how rubbish the standard factory welds are!
Bearings are arriving thick and fast so need to get the swingarm and forks sorted.
 

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teazer

Over 10,000 Posts
DTT BOTM WINNER
Anyone have any tips on a setup for the forks?
What weight oil, spacers etc?
Start with setting static sag. If it is too low, fit longer spacers and if it barely drop when you get on, the spacers are too long. Start with OEM springs and spacers and oil height and weight and work away from that.
 

Dazzo

New Member
Yep, I'm aware of static sag etc, I was just interested in people's experience of what changes they have done that actually work.
I would like to firm things up a little from standard.
 

teazer

Over 10,000 Posts
DTT BOTM WINNER
I understand that, but the only way to set up suspension on your bike to suit your weight and riding preferences is to measure what you have a decide if you need to change anything and if so which way and by how much.

If I tell you I had to make my forks stiffer and didn't tell you I weigh 300 pounds, that wouldn't be of much help. The bikes is (or should be) much lighter than stock and potentially will have a different weight distribution which is why I suggested you do what's right for you and ignore others who don't have the same combo and may not be as expert as they think.

Given the quality of work so far I figured you would start from scratch and work out what's best for you. But some desk research doesn't hurt if the OP knows what they are talking about. There are some very talented people that hang out here, but not everyone that posts knows much about how suspension should be set up.

That said, I would expect that stock soft springs might be OK after the weight loss but damping would probably benefit form fitting Gold Valves.
 

Dazzo

New Member
That, sir, is a very valid point.
I had kind of forgotten about the weight loss from the standard bike, added to the fact I only weigh 145lbs, I think your plan is correct, get the front built up with fresh oil etc and take it from there, I could well find it a little over sprung.
Thanks for your input
 

Dazzo

New Member
Temporary spray room set for the frame painting, the space has to be warm for the paint to work, I'm using the wrinkle finish stuff that gets used on car cam covers.
It's very tough once cured, but a pain to apply and has a particular technique, I have heaters set on timers for tomorrow so my shed should be warm as toast by the time I'm ready to paint.
 

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Dazzo

New Member
Well, so far so good, horrendous stuff to spray, everything around it gets sticky, very high gas off after painting.
But, it's looking like it's worked
 

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Dazzo

New Member
It's over some heat now until tomorrow morning, it will help cure the paint and tighten up the grain, it'll be as tough as powder coating in 48hrs.
 

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