GSX sheet metal seat pan build

[GSX Gilly]

After buggering up the paint on my 82 GSX250 I've decided to go all out and properly cafe it. I had looked at buying a 'glass seat but i couldn't live with myself having 'glass on my bike so I decided to build a sheet metal one. I already have the gs450 tank that I picked up on fleabay for $50.

It'll be fairly simple as I don't have any sheet metal tools and it needs to be big enough to fit in the battery.

I started out by bending some 10mm (3/8) round bar into the shape I wanted. I then cut some 1mm (18g) sheet a bit bigger than i need and bent it around the round bar. I cut another strip of sheet and tacked it onto the end the the first to make a skirt of sorts.

When i get some more time ill build the rest of the pan and finish up the welding.

I've also ordered a new taillight which is ADR approved to keep it legal.

 

[GSX Gilly]

I just remembered i probably should throw up some pics of the bike its going on and the bike that inspired it.

 

[YogiBear]

That seat is perfect imo. I love how it curves up in the back.

 

[GSX Gilly]

I do like that look with the swept up back.

I done a lil more, just after i posted my taillight turned up so i made a box for it.

 

[xratt]

imo, a little more recessed might look cleaner. But, I lovethe metal tail in general.I was designing one in my head and planning out a way to do it. It would pretty much look just like yours. Keep up the great work. Gives me more ideas!!

 

[GSX Gilly]

The light bucket has since been trimmed off, for some reason the light looks a bit odd in the pics but looks good in person. I'm happy with how it looks sitting on the bike, I just need to build some mounts for it.

Now the fun begins with the bodywork.

 

[polar8]

Can you post a view of the seat from the front? Specifically, the joint between the seat pan and the bottom edges of the seat cowl. I'm very interested to see how you did that.

 

[GSX Gilly]

I think you mean here?

The whole lot is just welded together and will be mounted from underneath

 

[Woodsy]

Hey Gilly that looks pretty good, You use a mig? I'd say an arc would be way to hot?

 

[crazypj]

Cool, never seen a GSX250 with that style tank(probably because learner laws in Britain changed and were limited to 12bhp, 125cc)
It's a reliable little motor, lots of potential with 4 valves per cyl (even though they are tiny valves)
Wouldn't go too 'retro', motor is too 'new' design.

 

[GSX Gilly]

Yeah i MIG'd it all, its easier and the welds end up nicer.

The original tank has been modified a little bit but this is what it looked like when i got it.

 

[polar8]

Yeah that picture is great! Noob metal working question- how do you get a rounded 90deg bend on sheet metal? My friend has a sheet metal brake but it only does sharp angles.

 

[rockcitycafe]

you bend it around a round form

 

[GSX Gilly]

I used the edge of my workbench as it has a 10mm round edge on it and just beat the metal over with a flat piece of timber.

 

[cargod78]

any progress? about to start my first one. might try a glass one first though