82 GS450E Scrambler from Aus - Done!

peteGS

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

There was something not right with the paint on the breather catch tank.

It was still a tad sticky to the touch this morning (well after the required 24 hours) and there were a few bubbly looking bits, so I decided to sort it out.

Gave it a quick sand with 400 grit paper tonight and got two light coats of paint over it.

After the 10 minute touch dry time, it already looked better than before, so that should sort it out I hope.

While I was rinsing it after the sanding, I let some water run in and it seemed to be water tight, and the tap allowed the water to drain, so hopefully it will both look and function ok.
 

peteGS

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

So she got a big bath yesterday as well as a polish and her first ever coat of wax. Real nice and shiny now! :D


I only had her out long enough to fill her for the week ahead so no paintwork pic's but I'm hoping to go for a good ride on the public holiday here on Wednesday so I'm hoping it will be nice and shiny and I can get some good updated pic's of her in the sun.


Also, between the bath and the wax, I got the seat and tank off and got the breather catch tank mounted up and connected.


Looks a lot better after the sand back and respray:





Cut a strip of rubber to give it some cushioning from the inner rear guard:





Drilled four holes in the inner rear guard and mounted it with cable ties with the rubber strip underneath:








Quick comparison of the old breather filter to the new... yeah it was oily and disgusting and had to go!





Then I ran the hose from the breather cover down to the catch tank, mounted the new breather filter, and all good to go:








Hopefully that tap holds up now and it goes ok.


The short trip around the block today wasn't really a good test run, but the commute to work tomorrow should be better for that and if I get to go on a good ride on Wednesday it will be even better.


I also marked the carry rack tonight where I need to cut it off to suit the grab rail when it arrives, so hopefully that won't be too far away and I can get a carry rack on there finally.
 

Hoosier Daddy

Earache my eye...
Re: 82 GS450E Scrambler from Aus - Breather catch tank done and on...

I have painted PVC pipe in the past and had the same thing you described. Wonder if it de-gassing on the intial coats. Glad yours came out better the second go.
Good luck to you on the ride to work, I am sure she'll do fine.
 

peteGS

Zuk's Rock!
Re: 82 GS450E Scrambler from Aus - Breather catch tank done and on...

Hoosier Daddy said:
I have painted PVC pipe in the past and had the same thing you described. Wonder if it de-gassing on the intial coats. Glad yours came out better the second go.
Good luck to you on the ride to work, I am sure she'll do fine.

Cheers HD! I reckon you're probably right, I noticed a few bubbles when I was laying the first coat down, but figured they'd go away when dry but no such luck. When I sanded it back the bubble revealed itself to really be a bubble, meaning there was a white circle of PVC revealed. There must be something in the PVC that reacts with the aerosol... oh well yes, second go was good :)

YogiBear said:
Looks nice and clean, Pete

Thanks mate! Pity about the glue in the vieiwing windows but still very useable I hope...
 

peteGS

Zuk's Rock!
Re: 82 GS450E Scrambler from Aus - Breather catch tank done and on...

I've started on what should be the last piece of the puzzle... a carry rack.

I really like the genuine optional sports rack so am attempting to make a replica given they're made of unobtanium, so I got another grab rail off eBay:



Took the aftermarket rack that was on the YB100 and chopped the mounting bit off the front:





And have now bent the lower rails out to clear the tail piece and allow them to meet up with the grab rail:



I now need to trim the ends of the rods down so they're all even and will put it level or slightly slanted up to the rear.

Then I'm going to be delayed for a few weeks until we get back from holidays when I can get a mate to weld it up for me. My welding sucks for something like that that will actually need the welds to be neat...

I also got out for a really good ride on Wednesday and the new catch tank held up well, no oil in it yet...

It was a really cloudy day and quite cold, but a great ride of around 230km's all the same, and I got some updated shots of the bike too:























 

peteGS

Zuk's Rock!
Re: 82 GS450E Scrambler from Aus - Breather catch tank done and on...

Ok, got the carry rack to the point of mock up:











And got time this avo to get the angle grinder out and cut the cross piece to size that will support the lower rails and stop them flexing under load:





Just need to get some heat so I can bend a loop that will attach to the top of the grab rail as a front mounting point, I can only bend 10mm solid steel rod so far without heat:





I also finally got the tacho drive replaced with the plug this avo.


Here it is in all its feral glory and I really need to ditch the dodgy Athena breather cover gasket as it is weeping just like the dodgy Athena valve cover gasket was:



One tacho drive removed:





And the plug with seal read to install with a shiny new stainless allen head bolt to replace the old one:





And installed:





This almost brings the 450 to completion, just gotta finish that carry rack and she will officially be "complete".


Then it will be onto the Duc...
 

peteGS

Zuk's Rock!
Re: 82 GS450E Scrambler from Aus - Breather catch tank done and on...

Wow this thread got old quick...


I've had some issues with her dropping back to one cylinder a couple of times but after swapping things around and checking everything out I could she started sparking on both again, and so far since then she's been great... no idea what actually fixed her though... unless of course it's not fixed and it happens again...


Anyway, my hands grips were dead after 4000km's:








It's getting a little chilly in the mornings now so I needed some neck gear as well as new grips:





New grips are great, soft and comfy foam and a little larger diameter make it a little easier on my hands so far as well:





I'm also sick of the tank bag on and off every day for work and there's a mark on the tank where some grit has gotten caught between the bag and paint, so I finally found a pair of panniers that will mount without sitting on the exhaust:








And they have a little colour insert you can stick in the outside pockets to colour code them to the bike as a nice little touch:





I've got them mounted a little higher now so they clear the exhaust well and truly and first trip to work and back today was good, so hopefully they go well and solve the luggage issue for me.


Now to get that carry rack finished up and she's all good!
 

MILLENNIUM FALCON

Over 1,000 Posts
DTT BOTM WINNER
Re: 82 GS450E Scrambler from Aus - Just a little update...

Now you just need to ship your bike over here and we can go camping :)
 

peteGS

Zuk's Rock!
Re: 82 GS450E Scrambler from Aus - Just a little update...

MILLENNIUM FALCON said:
Now you just need to ship your bike over here and we can go camping :)

Now wouldn't that be a blast! Gotta win me some lotto :D
 

interceptor

Coast to Coast
Re: 82 GS450E Scrambler from Aus - Just a little update...

Looking good Pete! Can't wait to see it with the luggage rack. Nice job.
 

Hoosier Daddy

Earache my eye...
Re: 82 GS450E Scrambler from Aus - Just a little update...

From the looks of those grips, you have really been enjoying her Pete!
Turning out to be quite the all-purpose ride.
 

peteGS

Zuk's Rock!
Re: 82 GS450E Scrambler from Aus - Just a little update...

Cafe Redneck said:
Bags look good on there Pete, I'll have to look for a set.


Cheers mate, proving very handy so far! Got my rain suit pretty much permanently in the left one and the work laptop and lunch in the right one and plenty more room available.


They're Oxford 1st Time Panniers, about $80 locally so in theory should be a similar price over your way...


interceptor said:
Looking good Pete! Can't wait to see it with the luggage rack. Nice job.


Cheers again! Yes I'm keen to get that luggage rack sorted, very annoying at times when I quickly want to strap something on and I really don't want it rubbing on any paint... I should hopefully be getting it welded together this Sunday if all goes to plan, which means then it'll just need some paint before fitting.


Hoosier Daddy said:
From the looks of those grips, you have really been enjoying her Pete!
Turning out to be quite the all-purpose ride.


Haha yes indeed HD! Been enjoying her to the max :D


I've done almost 4000km's since the rebuild and aside from the weird firing on one cylinder issue that still seems to be solved she's been going strong.


Next GSR run should be 16th June... can't wait for that one!
 

peteGS

Zuk's Rock!
Re: 82 GS450E Scrambler from Aus - Just a little update...

Dropped down to my mate John's place yesterday as he volunteered to do the welding for the carry rack, and we got it all welded up. My welding sucks big time so I'm really glad he took it on. He also had a thinner piece of rod that we ended up using for the cross brace underneath as well:





Now to strip it bare, get that chrome all roughened up, a light filing on a couple of the welds, then etch primer and paint.

I'm painting it black but not sure what paint just yet as I want it to be tough. I'm thinking the satin black I used on the dash and battery box cover will be ok but not 100% sure at the moment, will need to see what else is available. At least I know how that one lays down now though...
 

MILLENNIUM FALCON

Over 1,000 Posts
DTT BOTM WINNER
Re: 82 GS450E Scrambler from Aus - Carry Rack Welded Up

Looks great man! It is so nice to have somewhere to stick stuff. I don't know what I would do with out my panniers and rack.
 

peteGS

Zuk's Rock!
Re: 82 GS450E Scrambler from Aus - Carry Rack Welded Up

MILLENNIUM FALCON said:
Looks great man! It is so nice to have somewhere to stick stuff. I don't know what I would do with out my panniers and rack.


Thanks mate! And yeah, the panniers are great but I still need a rack... getting close to it now!


Spent a bit of time with a grinding wheel on the dremel this avo tidying up a couple of the welds we didn't get time to neaten up yesterday, then spent an hour and a half with 60 grit paper getting it ready for primer and it's about 95% there. Just a couple of rust spots on the chrome and a touch more paint on the grab rail part to go.





If I get to do that tomorrow avo/night then I should have time to prime it too.


I'll need to stop off on the way home and pick up some more 60 grit paper, wax and grease remover, and paint.


I'm gonna stick with the 3M satin black I used for the dash and battery box cover.
 

peteGS

Zuk's Rock!
Re: 82 GS450E Scrambler from Aus - Carry Rack Welded Up

Picked up the paint the other day, and bloody Supercheap has gone and changed brands again. They've gone from 3M back to Septone, so this time it's Septone satin black going on.





Then yesterday I finished the last little bit of sanding and got the etch primer on:





And tonight I got four coats of the Septone satin black on:











I'll bring it inside tomorrow night after it's sat to dry for 24 hours, then I'll leave it alone until probably Sunday avo/evening when it should be cured enough to mount it up.
 

YogiBear

Over 1,000 Posts
Re: 82 GS450E Scrambler from Aus - Carry Rack Painted

nothing like a freshly painted part. looks good, pete
 

peteGS

Zuk's Rock!
Re: 82 GS450E Scrambler from Aus - Carry Rack Painted

YogiBear said:
nothing like a freshly painted part. looks good, pete

Yes indeed, thanks mate! Can't wait to try it on for fit now... best wait 'til it's cured first though...
 

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