Progress thus far

Its been a crazy month, or month and a half, since I last posted anything on the progress of the motor cycle. Anyway, I haven't been lazy. School, work and life has taken time away from blogging, but alas, I'm back.

There has been a lot of progress on the bike. Here's the break down. I had to take the air box off so that I could make way for some new filters. Below is a photo of the bike taken apart minus the air box.


I got individual air filters for each carburetor.


Next up was the tank. I sand blasted the paint off the tank to actually see the condition of the metal. The inside of the tank was in rough shape and needed to be cleaned and sealed. I'm going to repaint the tank anyway so I figure, why not start from scratch. Surprisingly, it wasn't too bad. There were a few pin holes on the bottom where water has been sitting. I got patched up and prepped for paint.


I received the KBS tank sealer in the mail and went to town with it right away. It was a slow and long process, but that's what it took to do it correctly.







Next up, primer. I had to get a coat of paint on the tank right away. Bare metal and weather doesn't really mix well. And while I was at it, I redid the plastics as well. There was a little body work that needed to be done. I wanted to take the emblems off the side of the tank, and I needed to fill in the screw holes before I could lay down a coat of paint.


Here it is all put back together.




And a few shots of my nephew Lui on it.



This was about 3 weeks ago. Since then, I serviced the carburetor. I cleaned all the grime off of it, cleaned the jets, float bowls and made sure the gasket and o-rings were all alright. I also worked on the fuel valve, or petcock (yeah, Mina, I said petcock lol).

All that's left now is the wiring, rear tire, rear suspension, putting the carbs back on and I should be ready to fire it up and go for a test ride. Oh and I got new tail lights and marker lights that need to be installed.

Almost done, but there's alot left to be done. More to come.

GZ

A hiccup.

Have you ever tried to fix something, and when you start working on it, you keep finding things wrong? Well... this is a perfect example.

One of my main concerns about the GS is that the bike is an old bike. From what I've learned, my bike is actually considered a vintage bike, even though it was built in 1982. That said, I wanted to make sure that the tank is sound and clean. When I got the bike, I took a quick peek inside the tank and saw some rust, and I knew quickly that it needed to get taken care of.

I did some research and after talking to a bunch of folks about it, I decided to get this 3 step cleaning and sealing kit from KBS Coatings.



This would ensure that the tank is clean, rust free and sealed from getting rusty ever again (or so the company claims). All for about 30 bucks from Amazon.

So this past weekend, I took the tank off the bike, and took the petcock and float system (for the fuel gauge) off to start the cleaning and sealing process. I used duct tape, as per the directions, to seal the holes on the tank.

Aqua Clean was the first step. Its supposed to get the gummy stuff of the metal and really clean the inside of the tank to get it ready for the rust removing/inhibiting process. I mixed 1 part Aqua Clean to 1 part hot water and poured it in the tank. I sloshed it around for a good while and left it to soak over night.

The next morning, I drained the tank and washed it out real well with soapy water. During the draining I noticed chunks of rust was pouring out and some rust debris as well. This got me thinking... before I go with the next two process, I should go ahead and strip the paint to prep it for when I paint the tank, and I wanted to dig deeper and see what the condition of the metal actually is. So I took the tank to my friend Steve's shop to get it sandblasted. Steve has been very accommodating and has proven to be a valuable resource for me during this whole process thus far.

Sandblasting took the paint off and showed me some things I really was not looking forward to seeing... tiny little pin holes on the bottom of the tank. The rust had gotten so bad that it had eaten through the metal. The good part is that they are tiny. Steve took a look at it and found other weak spots from the rust, but they are still tiny. A total of 7 tiny holes.

This sparked more research on how to patch the holes in the tank. There's welding, brazing, JB-weld, putty, Bondo and the list goes on. I really don't feel like welding or brazing the tank since it involves fire... on the tank that has had gasoline in it. I can blow myself up some other time.... like never. JB-Weld just seems like a hack job.

Being that I'm sealing the tank anyway, the decision I've come to is to use a fiberglass patch over the holes, then use the tank sealant. The sealant will act as a liner for the tank so it should not leak. We'll see how it goes. If it doesn't work... a new tank will be on the horizon. About 200 bucks brand new, but at least it will be rust free from the start. =)

GZ

New bars. Hang on to something.

As per my last post, I mentioned that my roommate was kind enough to dock my rent by a $100 so that I could order some parts for the bike that he really wanted to see on there. Of course, I"m not gonna complain. Anything to see something new on the GS.

I also got the new air filters in a couple of days ago. One for each carb. I ordered them along with the new handle bars. I tried installing it one night after class, but the further along I got into it, the more I realized that it was gonna take some more planning than just slapping them on the carbs. I'll tackle that when I get a better sense of everything.

Anyway, the handle bars came in a few days later...today. I really do get a kick of waiting for a UPS, FedEx, or USPS package at work, which is where I get stuff delivered. Its like Christmas all over again and I don't have to wait til midnight or morning to open the presents.

After work, I couldn't wait to see how the bike will look with the new handle bars and bar end mirrors. The bars are Clubman style, very typical for Cafe Racer bikes. Its goingto give the bike a more aggressive look to it.

Here are the before photos of the bike with the old handle bars. As you can see, its plain Jane and the mirrors are fairly large. The ride style is very conventional.. in other words, boring.



After a few modifications to a couple of the parts and some rerouting of wires to accommodate the length of the bars, I was able to successfully install the new bars.





Before I installed the handle bars, I wasn't sure I was going to like how large the gauges were and how high they stick up from the bike. Looking at it now, I don't mind so much. I'd still like to see them in chrome.

GZ

The Seat. Wrap It Up.

So I kinda of procrastinated on the tank prep, but I did get some things done. There was a fiasco with how to get the gas out of the tank safely. I really don't feel like turning the tank over and pouring it out into a little gas can–it just didn't feel right. So I got a gas siphon from auto zone for a couple of bucks, and I should be able to get to it Friday afternoon.

This past Sunday, I figured I'd work on the seat again. So I went to Joann's Fabrics and bought some high density foam to pad the seat, and some cheap vinyl. I didn't want to get the good stuff until I'm ready to wrap the seat with the seat cover I designed later on.

First thing's first, the seat pan was bare metal so I needed to protect it from rust. So I painted it with some primer. I didn't have any other paint laying around, and Auto Zone had closed by the time I got to working. I figure that primer should do for what the foam will be laying on, and I'll paint the underside with some more weather resistant paint. I couldn't wait to get to working so, I unintentionally left off some steps. I'll just make sure to remember them once I get to the final.



Next up, foam. I had bought a bunch of high density foam to form the pad for the seat. I also picked up an electric carving knife to cut it. It worked like a charm, cutting through the foam like butter. Knife in hand and adhesive spray, I went to town. It was like art school all over again. Sculpting, forming and designing on the fly. Of course I already had the basic shape in my head. The goal is to end up with a cafe racer type seat. Here it is step by step, layer by layer.





After finishing up the basic form, it was time to wrap it in vinyl. This part was a little tougher than I had hoped for. Again, I forgot some steps. I bought a pop riveter to hold the vinyl in place. Unfortunately, I forgot to pre-drill the seat pan for the pop rivets. It was around 10pm when I realized it, and I didn't want to wake up the neighbors with drilling noises. Besides, I didn't have the proper drill bit. I'll get to it this weekend, but here it is all wrapped up.


Its not the prettiest job, but it'll do for now. I just need something to sit on besides bare metal or foam. I also need to re-carve some parts and lay down some smoother pieces of foam to even out some areas. As I've said before, its not perfect, but I'm just learning as I go.

My room mate was kind enough to take off a hundred bucks off my rent this month so I can buy more stuff for the GS... thoughtful isn't he? lol So I picked up the new handlebars and mini open element air filters off eBay. They should come in just in time for the week end.

The bike is transforming pretty nicely, but there's still a lot of work to do to make it safe to ride. Patience and taking things one thing at a time will be my saving grace from being overwhelmed, but I'm also really happy on how things are shaping up.

GZ

Weekend #2 - Tank Prep

So we're coming up on the weekend, and thank goodness, I've been wanting to work on the bike some more and get things done. There's a few things I want to get done this weekend. One of which is to seal the gas tank.

When I got the bike, one of the first things that I looked at was the gas tank. I wanted to make sure that there wasn't much rust in there. I opened the cap and saw more than a few rust spots. Not good. Rust deposits can damage the fuel system which can lead to engine damage. So I started researching on how to clean the inside of a gas tank.

I stumbled upon a few techniques on how to clean the inside of a tank. One of which involves BB's, diesel fuel, and gasoline. First, you drain whatever fuel that is in the bike and then remove it from the frame. Second, you take a half gallon of diesel fuel, pour it in the tank, followed by a handful of BB's and then you shake it up. What this does is that the BB's will knock off the dust particles in the metal and the diesel fuel will suspend the rust particles so it can be poured out after the process. After this step is done, you pour a half gallon of regular unleaded gas in the tank to get rid of the diesel fuel remnants. After which, the tank will be good to go.

Another processes I learned is cleaning the tank via electrolysis. The entire process can be found here... http://users.eastlink.ca/~pspencer/nsaeta/electrolysis.html. This is way too complicated and I really don't feel like playing with water and electricity in the same vicinity.

The other technique I found is a three step process of tank cleaner, rust remover, and a tank sealer. I bought a kit through Amazon.com from KBS Coatings. Here's the link... http://www.amazon.com/CYCLE-TANK-SEALER-KBS-Coatings/dp/B000IBDIX2/ref=sr_1_3?ie=UTF8&qid=1298612820&sr=8-3. Over all, this seemed to be the easiest and it the final step will coat the tank with a sealer that will protect it from all elements for the life of the tank—and I like that. =) This system is widely used in tanks that are around water all the time, mainly outboard motors, but it should work great on the bike. I'll try to remember to take photos, maybe some videos to post of the process.

The other thing I'm going to do this weekend is to strip all the old paint off and primer the pieces to get it ready for paint. Right now, the GS has 2 coats of paint on it, the first coat is the original blue color of the bike, and the second coat is the black enamel base paint that the guy I bought the bike from painted the bike with. I guess he didn't like the blue. I won't be painting the bike for another month or two, I just want to go ahead and get this step out of the way since it will be easy. I will go to town on the tank with a sand blaster and sand the plastic pieces (rear cowl and front fender) by hand since the sand blaster might be too strong for it.

The cowl does have a broken piece on it that will need to get fixed. One of the tabs that attaches the cowl to the frame is broken. I'm guessing that it was from someone trying to put the bike on the center stand and mistaking it for the handle below it. I'll be using plastic from one of the side covers to fix that tab with a fiberglass patch kit. This will save me around $50 for a used cowl off eBay, and about $130 for a new one from a parts store. The patch kit costs around $12 at Auto Zone.

I had a bit of free time this week so I decided to start working on the paint scheme and graphics for how I want the GS to ultimately turned out. Below is a quick drawing of the paint scheme...

It will be black with a metallic silver going down the middle and red pin striping on the edges. I also included the seat design that I will be making. I'll be using black vinyl on the sides and silver vinyl on top with red piping between the two. I'll be using red thread to stitch the two together.

As far as graphics goes, I'll be removing the emblem that is on the sides of the tank and replacing it with the Suzuki logo in the same metallic silver on top of the tank with red pin striping to out line it...


And as for the seat, I'll have the "GS650GZ" embroidered on black vinyl for the rear of the seat...


For the side covers, the "82" for the year model of the bike in black in the metallic silver circle with checker marks on each side...


This is the plan for now, but like I said, this step will be further down the road. The main focus is getting the bike running safely on the streets. I'll worry about doing the paint job later. In the mean time, I'll ride around with a black primered motorcycle. I also need to the the engine looking nice. So there's going to be a lot of cleaning, brushing, buffing and painting involved.

I just can't wait until the 15th to buy more parts.

To anyone reading this, I'm open for feedback on the paint scheme and designs. Let me know what you think.

Thanks!

GZ

The Look. Old Look.

I really admire old bikes. I also admire newer bikes that were made to look old. Just the idea of riding something that could potentially trigger memories and conversations from older people excites me. Nothing beats a trip down memory lane and sharing that ride with some one when they stop you because your bike reminded them of this one time, or when this happened. Hence my love for...

Royal Enfields...



Triumph Bonnevilles and Thruxtons




Ural motorcycles...



and Nortons...


I haven't had any of those experiences since I just got my bike. I have seen it happen to some friends who drive old muscle cars, and some older person stops and strikes up a conversation reminiscing about the time he fogged those rear windows up on a look out one night in high school with his sweetheart. The thought of being able to experience these things motivates me to keep working and cleaning up the GS.

Since my bike was built in 1982, its now considered to be a vintage motorcycle being that its over 20 years old—so that's a start. It does have a bit of modern styling since it was built in the 80's. It was right about the time that motorcycle design was taking a turn into the modern bikes. The old "standard style" was being phased out by Japanese manufacturers, or so it seems through my research.

One of the more popular things to do to these old Japanese bikes, 70's and early 80's models, are turning them into Cafe Racers. According to Wikipedia, "Cafe Racer" is defined as...

"A café racer, originally pronounced "caff" (as in Kaff) racer, is a type of motorcycle as well as a type of motorcyclist. Both meanings have their roots in the 1960s British counterculture group the Rockers, or the Ton-up boys, although they were also common in Italy, Germany, and other European countries. In Italy, the term refers to the specific motorcycles that were and are used for short, sharp speed trips from one coffee bar to another."

Basically, guys turned their little machines into faster cooler mode of transportation from one cafe to the next. These styling paved the way for modern sport bikes as far as looks. Triumphs, Nortons, BSAs and Enfields were the popular choices in those days since they were all readily available in Europe. These days, older Japanese bikes, since they closely resemble in style the European bikes of those days. Here are some examples....






The most popular Japanese bike to turn into Cafe Racer is the Honda CB750. With is styling and powerful DOHC engine makes it a perfect platform for a cafe racer, but other bikes, if done right, can be just as good. And that is what I will be trying to do with the GS.

As per my previous post, I mentioned that the seat pan has been fixed. Instead of matching the OEM seat, I will be attempting to make a cafe racer seat with a new cover. I'm trying to be as cheap as possible, but there are somethings that I will not be as thrifty with... and that is the way it looks and the way it runs. I figure I can offset the cost by doing the work myself. I completely understand that there are some things on the bike that I will have to have someone else do, and I'm fine with that. Provided those people do their job to the best of their ability.

I'm a pretty creative person, so I'm anxious to start thinking of changing the entire look of the GS that will hopefully spark the conversation I have been looking at having. =)

GZ

The Seat. Rust Be Gone.

Buying a 29 yr old bike definitely has got me a bit overwhelmed at times when I think about all that I have to do to make it safe and presentable. I keep telling myself that I have to take it one day, one weekend at a time.

Most of the things I'm running into is basically cosmetic parts that need to be redone. One of them is the seat. I thought about buying a cafe racer seat online, it would cost any where between $100 to $200. I thought that rather than risking ordering something online that might not fit on my bike, I could try and fix what's there already.

The seat's vinyl wrapping was pretty bad. It was torn at the seams, it had holes and cracks every where. When I took off the seat from the bike I turned it over to inspect the seat pan, and here's what I found...


The part of the seat that sits on top of the battery was rusty and corroded and was far from being saved. So I made a call to my friend Steve, who is a wizard with metal work to inspect my seat pan and see if it could be salvaged. (Check out his website at http://lonestarwelding.com/Home_Page.php.) I met Steve at THE Starbucks a while back. After many nights of hanging out drinking coffee, you get to make friends with people with all sorts of skills, talents, expertise and backgrounds. Steve just so happened to work with metal.

So I brought it over to him this past Sunday, he took one look at it and thought it could be salvaged. So we got to work. After taking the vinyl cover off, we got a better look at the condition of the foam. It wasn't in bad shape, but you can see where it had fused with some rust on the bottom and where water had gotten to it and made the foam crusty and moldy.

Steve had me sandblast the entire seat pan to get most of the rust particles and old paint off so that we could have bare metal to weld on. After much measuring, cutting, bending, shaping, and welding, this is what we ended up with...

The bottom...


The top...


Steve gave me a spray bottle of rust inhibitor to spray the seat pan down with. This will protect the bare metal from rust forming, and it neutralizes the rust that was left in the metal. After it dried I put it back on the bike.


This was the same day that I worked on the brakes. So I worked on the brakes while the seat pan was drying from the rust inhibitor.


I am fully committed to doing as much as I can with the GS. I'm taking it as an opportunity to learn new skills. So I tossed the old foam so that I will be forced to learn how to upholster a seat. So that I can be proud to say, "I made that." Thanks to Steve, I'm another step closer to finishing the GS.

I can't wait to get back at it this coming weekend.

GZ