82 GS450E Scrambler from Aus - Done!

peteGSX

Zuk's Rock!
Re: 82 GS450E Scrambler from Aus - Battery box cover and Acewell on...

And some shots from the aforementioned Katana forum run... sorry for the crappy quality but I only had the work iPhone with me. I was only able to join in the first leg of the run so only got shots from the starting point, but beautiful weather and all reports say an excellent day.


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Big R

Heaven is so far away.
Re: 82 GS450E Scrambler from Aus - Battery box cover and Acewell on...

Great pics Pete! I bet your Scrambler stuck out of the crowd a little bit.......

In the third pic down, what's the red and black bike in the top left corner? Katana I'm assuming........but did you get any other pics of it?
 

peteGSX

Zuk's Rock!
Re: 82 GS450E Scrambler from Aus - Battery box cover and Acewell on...

Big Rich said:
Great pics Pete! I bet your Scrambler stuck out of the crowd a little bit.......

In the third pic down, what's the red and black bike in the top left corner? Katana I'm assuming........but did you get any other pics of it?


Yes indeed it did Rich... just a little odd in there... haha


The red and black is actually an 1100 or 1150ES I believe... I don't have more pic's but I'm sure there were more on the GSR, will go look in a tick and will post up if I find 'em... it was a very nice example but all of us non-Kat riders took a bit of a voluntary back seat to the 7 Kats in attendance.


There's talk of another run in June, and I suspect this one will be a combined GSR and Katana Forum run, which means it should hopefully be big... would be great to get all the guys together in one spot, there is some awesome machinery there!
 

peteGSX

Zuk's Rock!
Re: 82 GS450E Scrambler from Aus - Battery box cover and Acewell on...


And I had a really smooth run home from work today for a change which gave me some extra time to get some stuff sorted here and even some time with the jigsaw to cut the awkward shapes out of both halves of the bracket.


IMG_4626.jpg



Then tonight I finished the cutting with the hacksaw:


IMG_4627.jpg



The gear position indicator fits in its slot neatly:


IMG_4628.jpg



And I'm not sure if you can see but I put a little chamfer on the rear to try to prevent any vibration causing the wires to rub against the alu.:


IMG_4629.jpg



Forgot to take more but I now have the slot for the gear position indicator marked out ready to cut out, hopefully tomorrow night although I have to work at 10:30 so that may not happen.


So far it seems to be coming together like I planned, so fingers crossed it will continue that way and it'll work out very neatly.
 

peteGSX

Zuk's Rock!
Re: 82 GS450E Scrambler from Aus - Battery box cover and Acewell on...

Here we go Rich, I did get a slightly better one, and looks like it's a GSX 1100ES:


photo5.jpg



I thought one of the other guys had a better shot of it but I guess not...
 

Big R

Heaven is so far away.
Re: 82 GS450E Scrambler from Aus - Battery box cover and Acewell on...

Thanks buddy! It's a great looking bike.
 

Hoosier Daddy

Earache my eye...
Re: 82 GS450E Scrambler from Aus - Battery box cover and Acewell on...

Great stuff! I like how you kept the gear change indicator... anxious to see how it turns out.
And those Kats are Kool!
 

peteGSX

Zuk's Rock!
Re: 82 GS450E Scrambler from Aus - Battery box cover and Acewell on...

Big Rich said:
Thanks buddy! It's a great looking bike.


Indeed it is Rich! Unfortunately due to having to cut the day short and only going on the first leg of the run I didn't get a chance to look at it in detail, but it certainly looked like a very nice example.


Hoosier Daddy said:
Great stuff! I like how you kept the gear change indicator... anxious to see how it turns out.
And those Kats are Kool!


Cheers HD! Haven't seen you posting much lately, so good to see a post from you again :)


I'm very keen to keep the gear indicator as I've grown very accustomed to having it... I'm missing it terribly at the moment!


And yup, Kats are very cool ;)


And as for how it turns out... more progress to follow...
 

peteGSX

Zuk's Rock!
Re: 82 GS450E Scrambler from Aus - Battery box cover and Acewell on...


Ok, first off... brace yourself for a fugly headlight pic:


IMG_4630.jpg



The very thin chrome plating came off when I bashed the dent in to clear the ignition switch and it has now nicely corroded... I really need to stick some primer on that or something to stop it rusting.


Anyway, that's the test fit of the bottom part of the bracket and as you can see it fits just fine, although I haven't bent it yet so the gauge doesn't sit at 45 degrees like it will.


Then I held the top piece on to get a rough idea of how it will go and it seems like it will be fine once I bend the sides down:


IMG_4631.jpg



Here's the bottom bracket finished as far as basic shape goes, and all I need to do with it is finish smoothing it off, drill the holes where I'll mount the voltage indicator and gear position indicator and the mounting holes for the top part. Oh, and paint it:


IMG_4632.jpg



And then I also got the cutout made for the gear position indicator face to slot through:


IMG_4633.jpg



Not too far off now once I get the sides bent down and mounting holes cut, although I haven't received the voltage monitor as yet.
 

Big R

Heaven is so far away.
Re: 82 GS450E Scrambler from Aus - Battery box cover and Acewell on...

I wish there was a "thumbs up" face - that would take care of half my posts in this thread........ :D

Great idea putting the indicator back in along with a voltmeter. Can you switch the clock for 24 hour to 12 hour? Or is that a personal preference?
 

peteGSX

Zuk's Rock!
Re: 82 GS450E Scrambler from Aus - Battery box cover and Acewell on...

Big Rich said:
I wish there was a "thumbs up" face - that would take care of half my posts in this thread........ :D

Great idea putting the indicator back in along with a voltmeter. Can you switch the clock for 24 hour to 12 hour? Or is that a personal preference?

Haha yeah they definitely need one of them, could've used a few in your thread actually!

I'm hoping it all works out as neat as it appears in my head... and yeah there's a setting on the Acewell to switch between them, but I've always preferred 24 hour time for some reason.
 

Hoosier Daddy

Earache my eye...
Re: 82 GS450E Scrambler from Aus - Battery box cover and Acewell on...

Code:
[IMG]http://www.city-data.com/forum/members/jill61-603505-albums-emoticons-pic61295-th-smiley-two-thumbs-up.gif[/IMG]

gives you this...

jill61-603505-albums-emoticons-pic61295-th-smiley-two-thumbs-up.gif
 

peteGSX

Zuk's Rock!
Re: 82 GS450E Scrambler from Aus - Battery box cover and Acewell on...

Hahahah nice one HD!



As for me...


Got the bottom bracket bent tonight and the top part bent to form the box as well:


IMG_4634.jpg



So it should end up looking something like this:


IMG_4635.jpg



Next up will be getting the mounts sorted so I can test fit it all.


No sign of the voltage meter yet but it's a bit early, so will organise that once it gets here. Plenty to do in the meantime...
 

MILLENNIUM FALCON

Over 1,000 Posts
DTT BOTM WINNER
Re: 82 GS450E Scrambler from Aus - Battery box cover and Acewell on...

Looking good man! That should work nicely for you.
 

peteGSX

Zuk's Rock!
Re: 82 GS450E Scrambler from Aus - Battery box cover and Acewell on...

MILLENNIUM FALCON said:
Looking good man! That should work nicely for you.


Cheers mate! It's coming together slowly.


I got a couple of holes drilled tonight for mounting the gear position indicator but that's about it, so no pic's at the moment.


I'm at the fiddly bit of working out where to put all the mounting posts and holes so I don't mess it up and have to start over from scratch.


I'm also still waiting for the voltage monitor to arrive from the UK so I can work out where it's going to sit.
 

SoyBoySigh

Been Around the Block
Re: 82 GS450E Scrambler from Aus - Battery box cover and Acewell on...

Damn, I had no idea that these old bikes even HAD a gear position indicator. One thing that I do know of having such a gizmo, would be some of the slightly more expensive Acewell gauges. Ha ha. I am sure you've been over this, but I just had to say it. I really like your build in any case, that scrambler pipe is bad ass. I would just love to throw one like that on my '82 CB750F. It's just brilliant. You know what I love on a high pipe though, that just screams "VINTAGE!!!" would be those little pipe guards. I had an SL100K1 when I was 16, back in '90 (and a CB100K0 from which I made a hybrid, using both rear rims, and the high pipe of course.... My damned neighbor stole the engine when I was in the middle of my move though. I went back up North to get the bike I'd been working on for months in a basement for cripe's sake, and the house hadn't been sold yet, I was just running back and forth. He'd asked me repeatedly if he could buy the engine for his kid's go-kart. One day, I am going to wind up in prison over this whole tale, so I should be careful what I say here.... Ha ha. It was a newly rebuilt engine and everything. Ugh.....) Anyway, yeah I just LOVED the guard on that old pipe. If I manage to fit up a high pipe, I'm looking at the awesome, new, and affordable, four into two into one from Cycle Exchange, and they have a plain header so you can fit up what you want to it. That's so cool. What would be even cooler, would be an "EXUP" valve down there too.... But yeah, it's GOTTA have a guard on it. Anyway, that's my two bits. Kinda feeling your frustration there over the gear indicator ... I can't even READ mine, and it doesn't even MOVE ... it's just carved into my sprocket cover on the left side of the engine where as hard as I crane my neck I can't read it. But it still works, if you get my meaning. Ha ha. But yeah, THAT, AND absolutely loving your scrambler exhaust. Too freakin' cool.

-Sigh.
 

peteGSX

Zuk's Rock!
Re: 82 GS450E Scrambler from Aus - Battery box cover and Acewell on...

SoyBoySigh said:
Damn, I had no idea that these old bikes even HAD a gear position indicator. One thing that I do know of having such a gizmo, would be some of the slightly more expensive Acewell gauges. Ha ha. I am sure you've been over this, but I just had to say it. I really like your build in any case, that scrambler pipe is bad ass. I would just love to throw one like that on my '82 CB750F. It's just brilliant. You know what I love on a high pipe though, that just screams "VINTAGE!!!" would be those little pipe guards. I had an SL100K1 when I was 16, back in '90 (and a CB100K0 from which I made a hybrid, using both rear rims, and the high pipe of course.... My damned neighbor stole the engine when I was in the middle of my move though. I went back up North to get the bike I'd been working on for months in a basement for cripe's sake, and the house hadn't been sold yet, I was just running back and forth. He'd asked me repeatedly if he could buy the engine for his kid's go-kart. One day, I am going to wind up in prison over this whole tale, so I should be careful what I say here.... Ha ha. It was a newly rebuilt engine and everything. Ugh.....) Anyway, yeah I just LOVED the guard on that old pipe. If I manage to fit up a high pipe, I'm looking at the awesome, new, and affordable, four into two into one from Cycle Exchange, and they have a plain header so you can fit up what you want to it. That's so cool. What would be even cooler, would be an "EXUP" valve down there too.... But yeah, it's GOTTA have a guard on it. Anyway, that's my two bits. Kinda feeling your frustration there over the gear indicator ... I can't even READ mine, and it doesn't even MOVE ... it's just carved into my sprocket cover on the left side of the engine where as hard as I crane my neck I can't read it. But it still works, if you get my meaning. Ha ha. But yeah, THAT, AND absolutely loving your scrambler exhaust. Too freakin' cool.

-Sigh.

Hahaha thanks mate! I love that pipe too, it's usually the first comment on get on the bike before they either walk away or look further. I've had compliments on it from people I never thought would even give it a second glance so that's pretty cool :)

I'm actually glad I'm keeping the stock gear indicator, it will make the Acewell look a little less modern once it's mounted up beside it, and yeah those other Acewells aren't exactly cheap! I think only the rectangular ones have that feature also which wouldn't suit what I want...

Always in the back of my mind is thoughts of a CL or DT (I think) style heat shield for the pipe, but if I ever do it'll be a while away... something neat and chromed would be the way to go :)

You'll definitely have to post up pic's if you do that with the CB!
 

peteGSX

Zuk's Rock!
Re: 82 GS450E Scrambler from Aus - Battery box cover and Acewell on...


Ok, I've managed a bit more progress over the last few nights and bits of time here and there, and it's at the point where it's basically all there and just needs a tidy up and smoothing etc.


I'm still waiting for the voltage monitor to arrive and that's the bit that's gonna kill progress very soon until it gets here.


So, mock up of how it should look with the gear position indicator:


IMG_4636.jpg



Cut the mounting posts to size:


IMG_4639.jpg



I filed them down smooth and to the exact right length after the photo.


All mounting holes drilled:


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Test assembly:


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I'm not using the cap head bolts in the final version, I'm waiting on some button heads to arrive instead. They were out of stock at the time but I needed to get something to test with and cap heads were all they had.


And mock up mount on the bike, and I have to turn the Acewell upside down while it's still mounted on the old bracket:


IMG_4643.jpg



And I got the perspex cut basically to shape and here's the test fit with it as well:


IMG_4645.jpg



Getting very close now...
 

peteGSX

Zuk's Rock!
Re: 82 GS450E Scrambler from Aus - New Dash/Acewell Bracket Coming Along...

Ok, close to as far as I can go before the voltage monitor arrives. Got some 60 grit sandpaper out tonight and smoothed all the edges off and got the acrylic perspex down to the right size and shape.


Gave the whole dash a go over with 240 grit to get it all smooth as well.


Aside from the voltage monitor mounting, the last thing I'll need to do is get some JB Weld going to fill up some gaps the bending has left in the corners and then it should be good to paint and assemble.


I really wish that voltage monitor would get here!


IMG_4646.jpg
 

Cafe Redneck

Been Around the Block
Re: 82 GS450E Scrambler from Aus - New Dash/Acewell Bracket Coming Along...

Great job, Pete!!! Vast improvement over those big ugly ass Suzuki gauges.
 

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