82 GS450E Scrambler from Aus - Done!

peteGSX

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

Cafe Redneck said:
Great job, Pete!!! Vast improvement over those big ugly ass Suzuki gauges.


Thanks mate, certainly is! More done tonight and she's almost ready for paint...
 

peteGSX

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


Ok, so the button head stainless bolts and the voltage monitor arrived today.


IMG_4647.jpg



So I gave the voltage monitor a little run on my test setup with variable voltage and it all worked like it should, and I tried with the link installed and it will definitely double as a battery monitor as well. Nice, very happy with that!


One of the guys over on the GSR suggested I add a momentary switch to switch it over into battery monitor mode, and that idea is going ahead:


IMG_4648.jpg



That's just a momentary push button mounted underneath to keep it away from the weather as I couldn't find a small enough weatherproof one.


Basically, holding that in while I turn the key on will put it in battery monitor mode instead of voltage monitor mode. Simple.


So, given I have the perspex cover over the dash, I needed to recess the monitor under the perspex, so I made a little bracket to mount it to the lower part of the dash. I need to adjust it a bit as you'll see later on:


IMG_4649.jpg



And the final mock up:


IMG_4650.jpg



And some quick final testing:


IMG_4651.jpg



If you look closely you'll see the LED for the voltage monitor is a little too far left and low for the hole, which is what I alluded to in the earlier comment about needing to adjust the bracket. Should be easy.


And a quick couple of videos, first in over voltage condition:


th_MVI_4652.jpg



And in under voltage condition:





So, once I adjust the bracket for the monitor, it's out with the JB weld finally to seal up the gaps and do a general tidy of some marks and things, then it'll be sand, clean, etch primer, then paint.


Can't wait for it to be done!
 

Big R

Heaven is so far away.
Re: 82 GS450E Scrambler from Aus - New Dash/Acewell Bracket Coming Along...

This is coming along really well Pete. I haven't been on the GSR much lately, but I'll have to read the details over there as well.
 

peteGSX

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

Big Rich said:
This is coming along really well Pete. I haven't been on the GSR much lately, but I'll have to read the details over there as well.


Cheers Rich! Everything over there is pretty much copy/paste to here, so not missing much except some other guy's replies really...


I'm so keen to get this done because the Acewell sits just a little too far to the right for my liking.


And for tonight's work:



I got the mount for the voltage monitor aligned properly with the hole tonight and sanded the bottom bracket down to start preparing for the etch primer:


IMG_4655.jpg



The mount looks a bit twisted and ugly now but it does the trick nicely.


I also got the JB Weld done to fill the gaps between the bent down sides and also to fill a couple of low spots:


IMG_4657.jpg



IMG_4658.jpg



I'll let that cure overnight and hopefully tomorrow night I'll be able to sand it back and maybe even get the etch primer done depending on the weather. They're predicting a possible shower or two so it may or may not be good painting weather.


I also made the most of having two multimeters at my disposal and compared the voltage at the battery with the voltage on the switched output from the ignition switch.


I'm dropping less than 0.3v through the ignition switch, so I should be safe to use that as the source for the voltage monitor. It's not perfect by any means but should do the trick.
 

peteGSX

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


Got it in etch primer tonight!


Firstly though, I was thinking about the voltage monitor and how I wasn't real happy about it being out by the 0.3v I'm losing through the ignition switch, so I ducked out and picked up a horn relay today so I can have it measuring direct from the battery via the line running to the clock in the Acewell.


IMG_4659.jpg



Tonight I got the cover all sanded back ready for primer:


IMG_4660.jpg



IMG_4661.jpg



Set up the drop sheet out the back and got them hung up and cleaned up with some wax and grease remover:


IMG_4662.jpg



IMG_4663.jpg



Then got two coats of etch primer on:


IMG_4666.jpg



I think I got some runs because I was trying to get into the fiddly bits around the voltage monitor mount, so I expect I'll need to do a little bit of light sanding before spraying the black on.


So, while they started to cure, I had some thoughts on how to wire things up in the dash. I need to get switched 12v to the voltage monitor and the gear position sensor, and I need to connect the momentary switch to the voltage monitor so I can flip it over to battery monitor mode.


The relay mentioned earlier will sort out the switched 12v issue, but I needed some terminals to plug onto the provided pins on the voltage monitor that puts it into battery monitor mode.


So, I ripped my computer case off and found some unused terminals in there, so I cut them off to use for this:


IMG_4667.jpg



I took the plastic enclosures off as I'll heat shrink them once I've got them connected to the switch, and here's where they connect to the voltage monitor:


IMG_4668.jpg



Then I threaded the voltage monitor wires down through the gear position sensor sheathing to give me an easy way of getting it down to the end of the Acewell harness:


IMG_4670.jpg



And, finally, here's the wiring diagram for it all:


IMG_4671.jpg



If all goes to plan I should be able to spray the black tomorrow night which means it should be right to mount up maybe Sunday night, can't wait!
 

peteGSX

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

Got a couple of things done last night.

I was running low on the satin black, so the dash has three coats of satin black all over, but I did the extra three coats on the front of the dash and the top of the bracket where it bolts to the triple clamp:

IMG_4674.jpg


IMG_4676.jpg


Then between coats waiting for flash off time I got some wires and the pins on the momentary switch and got some heatshrink over them:

IMG_4677.jpg


So it will happily plug into the posts on the switch so I can switch to battery monitor mode on startup:

IMG_4678.jpg


All I've gotta do now is sort out the rest of the wiring for the relay and once it cures I can put it all together finally
 

Hoosier Daddy

Earache my eye...
Re: 82 GS450E Scrambler from Aus - New Dash/Acewell Bracket Coming Along...

I'm excited to see the finished product! Looks good from here so far.
 

peteGSX

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

Hoosier Daddy said:
I'm excited to see the finished product! Looks good from here so far.


Give me about a minute and you'll see it ;)
 

peteGSX

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


Ok, three hours in the garage last night yielded an installed and wired in new dash :D


Got it fully assembled with the nyloc nuts and relay on the back:


IMG_4680.jpg



IMG_4681.jpg



Next I spliced in a wire from the ignition switch to turn the relay on and off with the ignition:


IMG_4683.jpg



I got all the crimp terminals on the wiring and hooked up to the relay ready for installation:


IMG_4684.jpg



You can see the momentary push button switch in the bottom right corner there which will allow me to switch over to battery monitor mode while the ignition is on.


And got it all bolted up and wired in. Excuse the filthy fly screen, she's in desperate need of a spit and polish but haven't had time for weeks and they reckon it's gonna be raining again this week...


IMG_4688.jpg



IMG_4689.jpg



IMG_4687.jpg



Test ride today to work and back, and man it's nice to have that gear position indicator back!


So far so good...


I'm also sick of seeing this:


IMG_4682.jpg



A little bit of blow-by dripping from the breather filter up under the tank results in a big mess on my new battery box cover... so I'm going to make a catch tank out of some PVC pipe I have laying around, and I still have plenty of 12mm hose too:


IMG_4699.jpg



IMG_4679.jpg



So far, I've worked out it will go here:


IMG_4694.jpg



I'll have the filter on the right end where I'm holding it so it's on the high side with the bike on the side stand, then I'll have a drain tap on the left side and the breather hose will go in the left side also.


Marked out where I will put the fittings and got the pilot holes drilled and those two half pieces you see there are getting glued inside so I have a thicker layer of PVC to mount the fittings in:


IMG_4695.jpg



Then I got the second layer of PVC in with some glue (if you look close you can just see the pilot holes are now stopping at the second layer):


IMG_4696.jpg



IMG_4697.jpg



Then I got a little disc of the PVC to mark out the circles I'll cut out of some of the scrap acrylic perspex for the ends so they can double as viewing windows for the level:


IMG_4698.jpg
 

sham

Been Around the Block
Re: 82 GS450E Scrambler from Aus - New Dash is On!

New dash looks awesome Pete. All these parts you're making are really cool.
 

peteGSX

Zuk's Rock!
Re: 82 GS450E Scrambler from Aus - New Dash is On!

sham said:
New dash looks awesome Pete. All these parts you're making are really cool.

Thanks mate! Very happy with it, and that Acewell is just spot on exactly what I wanted.

Once I finish the breather catch tank, there's just a rear carry rack and she'll be 100% done :D
 

peteGSX

Zuk's Rock!
Re: 82 GS450E Scrambler from Aus - New Dash is On!

Speaking of the catch tank, I got the perspex end caps cut out yesterday and the inlet side of the tap trimmed down so it would sit flush with the PVC pipe:

IMG_4700.jpg


Got the fitting and tap holes drilled and I filed the area flat around the tap hole to give the glue the best chance of bonding it well:

IMG_4701.jpg


IMG_4702.jpg


IMG_4703.jpg


Fittings screwed in, and they're a nice tight fit with the second layer of PVC I put in there:

IMG_4704.jpg


And the tap glued on and held on with masking tape to hold it while it bonds:

IMG_4705.jpg


I sanded the areas around all the holes so I just need to give the rest a quick sand and clean, mask the fittings and tap off, then it's time for the black plastic paint.

Once that's done, I can get the perspex end caps glued in and mount it up ready to go.
 

MILLENNIUM FALCON

Over 1,000 Posts
DTT BOTM WINNER
Re: 82 GS450E Scrambler from Aus - New Dash is On!

I agree! hey Pete, why don't you fly over to Pennsylvania and help me finish my 400 ;)


MotorbikeBruno said:
Your stuff is so clean looking. The dash is great!
 

peteGSX

Zuk's Rock!
Re: 82 GS450E Scrambler from Aus - New Dash is On!

MotorbikeBruno said:
Your stuff is so clean looking. The dash is great!


Thanks mate! I'm real happy with it and it's had the rain test on the way to work yesterday as well...


MILLENNIUM FALCON said:
I agree! hey Pete, why don't you fly over to Pennsylvania and help me finish my 400 ;)


Cheers! Mate I'd love to come over and see that beast in person... then go visit Rich and get a good look at his GR's... maybe one day... haha


Cafe Redneck said:
Great work on the dash!!!


Cheers mate! Ditto the above, very happy with it :D
 

peteGSX

Zuk's Rock!
Re: 82 GS450E Scrambler from Aus - New Dash is On!

I got the breather catch tank all sanded down, cleaned, masked, and hung up for paint tonight:


IMG_4706.jpg



Then four coats of this:


IMG_4709.jpg



IMG_4708.jpg



I also got the perspex end caps filed down so they should slot in the ends nicely so they can be glued in place.

Gotta wait 24 hours for the paint, then the end caps can go on.I won't mount it up yet, I'll wait until after she's had a big bath which I should get done on Saturday, and that way I can make sure there's a difference and no oil ending up on the battery cover.
 

peteGSX

Zuk's Rock!
Re: 82 GS450E Scrambler from Aus - New Dash is On!

Here it is:


IMG_4717.jpg



The paint should be dry tonight but it still felt a touch sticky to me so I just took it easy with it while I got the end caps glued in.

I did have one issue though which was the tap coming off when turning it on and off... bugger! Not sure if the glue is the right stuff as I have no idea what the tap is made out of.

For now I've stuck it back on again and added a couple of cable ties for support, so hopefully that's enough otherwise I have to find something else to glue it with.

Anyway, here it is with the end caps on, and the glue unfortunately has run a bit on one side, but I'll still be able to see the level:


IMG_4718.jpg


IMG_4719.jpg


I should be washing the bike on Saturday, so I hope to be able to mount this after doing that so the next time I start her after the bath I won't have blow by landing on the battery cover again...
 

peteGSX

Zuk's Rock!
Re: 82 GS450E Scrambler from Aus - New Dash is On!

Big Rich said:
Great work as always Pete.

Cheers Rich, although I'll reserve judgement on this bit until I've proven if that glue holds up in the long term... however as long as it stops the mess I'll be happy :)
 

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