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Old 12-14-2012, 08:13 PM   #31
Ryan5544
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Cool ass bike! Good job!


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Old 12-15-2012, 07:08 AM   #32
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Re: 8Ball's Winter Cafe Project

Thanks!

Miller'sR6, how comfortable was that bike to ride? Of all the bikes I have owned and ridden I never had a hard tail!
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Old 12-20-2012, 08:30 AM   #33
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Re: 8Ball's Winter Cafe Project

i wish i had that kind of patience .. nice work !
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Old 01-18-2013, 05:23 PM   #34
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Re: 8Ball's Winter Cafe Project

It's been a while since I updated this thread.* I have done a few nickel and dime items and have continued working on the rearsets and linkage layouts:

First, the rear brake linkage set-up:

I cut off the brake pedal:


Made a tab for the linkage:


Shaped, drilled and welded the tab to the brake pedal clamp:


Cleaned it up a bit (had to grind off the rest of the chrome for paint eventually):


Here it is installed with the link attached:


...but why, you ask, did I use a shackle with a removable pin instead of a heim joint on the front joint?
Well, I'm glad you asked!* The kick starter cant be used with the rearsets in their normal position:


...so I made it so you fold the peg, and disconnect the linkage (without tools) and flip the brake pedal out of the way, and Voila!* The kicker* is functional!


Next, the shifter side:

As I mentioned before, the shifter that was included in the set pointed up, but this would cause issues with the linkage,


...so Kris Richardson from Old School Speed sent me a shifter that pointed down:


I drilled off the original ball joint from the shifter link:


And here it is...


Finally, the rearset brackets needed to be trimmed down to get rid of the excess:


With only an angle grinder and a bench grinder....not too bad, if I say so myself:


and here it is installed:


I need to get some 1 inch spacers made out of 1-1/4" round stock to replace the sockets I have between the brackets and the pegs, and I need to find some place to counter bore the mounting holes so the bolt heads will sit in a bit, then I can paint them.
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Old 02-09-2013, 02:40 PM   #35
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Re: 8Ball's Winter Cafe Project

OK, it's been a while...mainly 'cuz I've been out of town, but I got home and today I got back to the GS:

Today I started to work on the electrical component tray. First the general shape was cut out of cardboard:


That was transferred onto the sheet metal, and cut out:


Using my backyard sheet metal break, I got the bends done...


Then I laid out the components where they will end up. Man that Shorai battery is small! (2.25" X 3" X 4", and about a pound):


The rectifier will end up mounted on the bottom of the tray so it will get plenty of cooling air.
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Old 02-20-2013, 05:42 PM   #36
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Re: 8Ball's Winter Cafe Project

Today I finished up the electrics:

And after I made the tray, and got everything mounted and laid out the wiring:


I did have to lengthen the cable from the starter to the starter relay, and make a new negative batt cable, so I had to figure out how to crimp a 6 gauge wire terminal without spending a bunch of money on a crimper.* So I used my AMP crimper in the 10 gauge slot to start the crimp, then finished the crimp in a vise.* Then flowed solder into the crimp for a complete connection.* Ugly, yes, but 100% connected:

This is where all the electrical components used to be, behind the side panels:


...and this is how it looks, now:




Tune in next time when this gauge cluster get fluster chucked! ...or, Fun with LED's
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Old 02-20-2013, 05:52 PM   #37
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Re: 8Ball's Winter Cafe Project

first bike was a 1980 gs850gl man I loved that bike!
can't wait too see how yours turns out!
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Old 02-22-2013, 03:20 PM   #38
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Re: 8Ball's Winter Cafe Project

...so the original cluster is an abomination, IMO, so I gutted it and painted the gauges (mentioned in a previous post). I still wanted the indicator lights, so I took the inside housing and flipped it upside down:


Then I cut a plate out:


and mounted it on the housing:


One of the light socket holes was unused, so I used it as a mounting point:


Drilled holes for the LED's and painted it black:




And done!

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Old 03-05-2013, 02:49 PM   #39
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Re: 8Ball's Winter Cafe Project

Update time:

These cheap Chinese RFY shocks were included in the pile-o-parts I got with the bike.


CrazyPJ, from one of the Cafe racer forums is the only person that I have found that has rebuilt these things, and he states that they are not bad, but out of the box, they don't have enough oil, or Nitrogen. And I found that to be the case with mine...

....so it's "service time". And a HUGE thanks to PJ for answering my few...OK, a dozen....questions. Between PJ's help and the following video from Youtube, I was ready to tackle a set of shocks for the first time.


First, I bough an adjustable pin spanner wrench I found on eBay for 6 bucks (also good for my angle grinder)


Next, I need a spring compressor..which I don't have...but I do have a bead breaker on my tire machine:

..and the center stand that was removed from the GS...

...and some flat stock...and a vise...


Some creative use of a tie down to stabilize it, and now it's a make shift spring compressor:


With the spring off and the seal retainer removed (with the pin spanner wrench) I cut an 8" piece of tubing off of an old porch swing this is in the scrap heap. With the spring seats, a couple of washers and the shock shaft nut, I used the tubing as a puller to pull the shaft seal.


Here it is disassembled:


To reassemble, I followed the youtube video, with a few small modifications for the differences in design. In Crazy PJ's build, he drilled and tapped the shock body to install a bleed screw in this spot:


I didn't have a way to counter bore the hole to accept an o-ring, so I didn't do it. It isn't necessary, but it is a great idea, and allows you to get every bit of air out of the shock.

Here they are re-assembled. I took them to a tire store and had them charge them with 75 psi of Nitrogen.


Job done. Oh, I used 10 wt fork oil. We'll see how well it works. I might need to go up or down in weight.
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Old 03-07-2013, 10:37 AM   #40
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Re: 8Ball's Winter Cafe Project

Quote:
Originally Posted by 8Ball View Post
Thanks!

Miller'sR6, how comfortable was that bike to ride? Of all the bikes I have owned and ridden I never had a hard tail!
Sorry first time on in a while. It was not too bad the springer seat helped out. I never really rode more than an hour on it though.
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