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Milge
01-16-2017, 7:48 PM
I'm gonna chop this GS450. Backstory: This was my first bike. I bought it unrunning off of CL for a few hundred bucks 4 or so years ago. I did what was cool at the time and cafed it. I was pretty happy with the way it came out. I did everything to it except replace the wiring harness. And the wiring harnesses on GS450s suck. I rode it my first season of riding to learn riding. And it was good. My second year of riding, I picked up a sporty, and there she sat in the garage. After a year or so untouched, I put her up on Craigslist. She was sold in a day. Fast forward to this year around july. I had just totaled my sporty. I randomly hopped on CL for something to build only to find my cafed GS450. I bought it and brought it back home. It had gone through 2 owners and back to me. It was an incredible feeling getting my first built bike back randomly.

I have a little free time right now and decided to rebuild the wiring harness so the bike is 100%. Took the tank and seat off and a ding went off in my head. I grabbed a few old stock harley parts and threw em on. I wrestled around in my head for a few days whether or not to chop the frame. I think it's beautiful. But this frame is getting chopped. Here's some pics.

http://i.imgur.com/DNcSgwsh.jpg

http://i.imgur.com/vhuMgRgh.jpg

http://i.imgur.com/6OsM2yph.jpg

http://i.imgur.com/RFcNibKh.jpg

Milge
01-17-2017, 9:00 AM
I measured front and back wheels and both are 18". I'd like to run a 16" x 3" cast rear wheel and convert it from drum to disc. Anyone know of any other options besides the comstars that would fit well and look nice?

Westboundbiker
01-20-2017, 11:22 AM
I did a GS build a couple years ago. Those aren't comstars on it- Honda had those, these are just mags. There was a stock spoke rim on the T model GS, but those are few and far between.

When you hardtail it, you can actually use removed frame bits, at least I did.

Here's my build, for reference: http://www.chopcult.com/forum/showthread.php?t=39594

Milge
01-20-2017, 10:47 PM
I did a GS build a couple years ago. Those aren't comstars on it- Honda had those, these are just mags. There was a stock spoke rim on the T model GS, but those are few and far between.

When you hardtail it, you can actually use removed frame bits, at least I did.

Here's my build, for reference: http://www.chopcult.com/forum/showthread.php?t=39594

Solid build! I came across it in my research. Looks great. That back triangle and crooked motor mounts are a real bitch eh?

I ordered a 16" GS rear rim on fleabay which should come next week. I'll run the 18" on the front. Motor comes out tomorrow.

Milge
01-21-2017, 11:00 PM
Removed the motor and rest of the electronics today.

http://i.imgur.com/JdSY3rSh.jpg

http://i.imgur.com/f7FjBWqh.jpg

http://i.imgur.com/Su6xHGUh.jpg

Milge
01-31-2017, 12:40 PM
The rear 16" wheel came and it looks great.
http://i.imgur.com/ZW6ggZSh.jpg
Parts for a frame jig
http://i.imgur.com/d02TwISh.jpg
Rough mockup of the jig. The neck mount will be done soon.
http://i.imgur.com/9IHqO89h.jpg
Removing the old paint sucked. Half I did with paint remover, the other half with a soda blaster.
http://i.imgur.com/vT1fhHyh.jpg
http://i.imgur.com/VOahKUzh.jpg
http://i.imgur.com/BrecASch.jpg

Milge
02-19-2017, 6:34 PM
Brought the motor inside to work on it when it's cold out. Replaced these seals since one had a leak.
http://i.imgur.com/bAYqnm6h.jpg
Did a valve job. Had to order 2 new shims. The valves are now smack dab in the middle of spec.
http://i.imgur.com/6TG6bWxh.jpg
The start of some axle plates.
http://i.imgur.com/3UGkWYPh.jpg
Chop chop. Cut out the backbone right past the detent but left the two side rails. Welded the backbone in using the side rails as reference to make sure it was straight. Next I cut off one side rail and welded the middle tube up into the backbone. Then I did the same to the other side. These suzuki frames are all kinds of uneven from those middle tubes backward.
http://i.imgur.com/E8zQ7PDh.jpg
I don't like how everything came out with the middle tubes up by the backbone. You can see the closer one is all wonky. The far one is a little off too. I did pie cuts and tig welded them.
http://i.imgur.com/8vhEJOHh.jpg
You can see what I mean.
http://i.imgur.com/GlxMfXFh.jpg
Went back and redid the closer side. It looks much better now. Still have to redo the further side, but you can see what I mean. Also cut the rest of the seat off.
http://i.imgur.com/bfRecPnh.jpg

Milge
02-28-2017, 8:43 PM
Finally got the frame welded up. I'll still have to do some support up by the neck, brackets for footpegs, and a few other odds and ends, but it's coming along nicely.

http://i.imgur.com/nvCVRy2h.jpg

http://i.imgur.com/HaqvtmWh.jpg

Really starting to like the way this is looking.

http://i.imgur.com/x5KFpAbh.jpg

http://i.imgur.com/qIVwj7bh.jpg

http://i.imgur.com/ybUsmL5h.jpg

Next I'll be working on the seat and gas tank. Probably gonna do a springer seat. For the gas tank, I'll be converting this 2 gallon tank off of a '14 sportster. Got a question for the experts. This tank is an EFI tank and has the overflow tube that comes out of the bottom. The petcock on the original tank is a vacuum petcock with 2 lines, a gas line and a vacuum line. I'm not sure whether the original tank had a vented cap or not. Will I need a vented or nonvented gas cap for the sporty tank? I know I'll have to make an adapter to go in the large hole in the bottom of the sporty tank and in that adapter, slot a hole for the original vacuum petcock. My question is will this work as I describe it? The original tank didn't have any overflow tube. So I'm not sure if the original tank was a "sealed" vacuum and the sporty tank isn't "sealed." Will using this sporty tank work with the vacuum petcock? From my research, the vacuum line is used to open the diaphragm in the petcock. Does the tank being vented or not matter? Or will I run into issues?

Milge
03-14-2017, 6:19 PM
Started the final fitting so I can do all of the details.
http://i.imgur.com/liQ6Jx7h.jpg
Sealed the EFI hole and made a new one for the suzuki petcock.
http://i.imgur.com/eoP47Lfh.jpg
Got the hole in the frame drilled to mount the front of the tank and the clearance is less than 1/4"
http://i.imgur.com/d22hk1Wh.jpg
Also small clearance between the petcock and carb.
http://i.imgur.com/EIWsJRvh.jpg
Fabricated an electronics box that will go between the fender and motor.
http://i.imgur.com/vAEll3uh.jpg


Ordered a 6" wide fender. Also shortened the long back mount of the tank by 2". Going to be making a headlight mount and foot peg mounts next.

Milge
04-10-2017, 6:10 PM
Made a headlight bracket.
http://i.imgur.com/0HsVZoBh.jpg
Sanded the tank and headlight. Also sealed the tank with redkote.
http://i.imgur.com/xr74ULeg.jpg
Coils are getting mounted under the seat.
http://i.imgur.com/Tdcqht7h.jpg
Ignition is going here
http://i.imgur.com/jtL9CjSh.jpg
Fabricated a pair of adjustable foot pegs. They slide forward and back a little bit.
http://i.imgur.com/Xgw3uK5h.jpg
http://i.imgur.com/go8Qvq5h.jpg
http://i.imgur.com/wrC6Bknh.jpg
Been busy with all the small odds n ends. Made a seat pan and had a seat made. Made a sissy bar.
http://i.imgur.com/4whstwAh.jpg
Just broke it all the way down earlier for final welds, sand, and paint. Gotta do neck supports and the coil mount under the seat. The last 5% takes 95% of the time.

Hotel
04-11-2017, 3:17 PM
Really digging this build.
Will be watching.
+2 on the flamingo in the background.

Fings369
04-18-2017, 10:49 AM
About to scoop one this week, What jet sizes are you using? I'm going to start with 127.5 mains and 30 pilots... figured I'd ask since I'm not too far.

Milge
05-17-2017, 5:59 AM
About to scoop one this week, What jet sizes are you using? I'm going to start with 127.5 mains and 30 pilots... figured I'd ask since I'm not too far.

I actually don't remember. I did it years ago. I do remember having to shim the needle. I'll probably do a plug chop soon. If I have to change my jetting, I'll update this thread.

I got the build finished. Got everything painted. Wiring was a real pain in the ass. Right now I'm just ripping it around the neighborhood in case it breaks down on me. The neighbors must love me. I'll take it on it's first distance ride in a couple weeks or so. And I'll update the thread with better pics when it gets nicer out.

http://i.imgur.com/WkljTZyh.jpg

http://i.imgur.com/NsZHhZZh.jpg