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  1. #1
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    Default Suzuki GS500E Scrambler.

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    Starting point.

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    I try to build something completely new from this clunky frame.

    Honda tank from the 60s, scrambler seat, the back of the chassis need mod and so on.
    Last edited by BobberFreak; 02-05-2019 at 12:07 AM.

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    Quote Originally Posted by BobberFreak View Post
    Click image for larger version. 

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ID:	90834
    Starting point.

    Click image for larger version. 

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    I try to build something completely new from this clunky frame.

    Honda tank from the 60s, scrambler seat, the back of the chassis need mod and so on.
    I do not think this marriage will work.
    The aluminum road frame is just not up to a steel scrambler frame.
    I would start with a different frame. Different wheels too. Headlight is way too large.
    Ill advised project.

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    Quote Originally Posted by BobberFreak View Post
    Click image for larger version. 

Name:	20190106_193009.jpg 
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Size:	304.0 KB 
ID:	90834
    Starting point.

    Click image for larger version. 

Name:	20190128_091953.jpg 
Views:	19 
Size:	322.3 KB 
ID:	90835
    I try to build something completely new from this clunky frame.

    Honda tank from the 60s, scrambler seat, the back of the chassis need mod and so on.
    You need to throw that whole frame away for that to work.. why didnt you buy a steel framed 70/80s bike instead? Put this one back together and buy something more possible to scramblerize..

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    Thanks for the suggestions, gentlemens

    It is true that the easiest way would be to use 70/80s frame, but..
    I build this motorcycle on the terms of the existing material and therefore it makes this project challenging and interesting.
    The project is just beginning and i have a strong credit for this but it`s need a lot of work to make it good looking.
    At the moment, the back of the body is removed and self-made seat frame is under preparation.

    I'll update more photos as the project progresses.

  5. #5

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    I say stick with it! I kind of dig the direction you are taking it so far. We've all seen your typical "scrambler" a million times over.

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    Quote Originally Posted by mx425 View Post
    I say stick with it! I kind of dig the direction you are taking it so far. We've all seen your typical "scrambler" a million times over.
    This!...Build what you want and ride the wheels off it regardless of all the naysayers..I got the same negative feedback from my project Dirt Bag-R...With all the rain last year I rode it more than my Chop..
    https://imgflip.com/i/2t2qt9

  7. #7
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    Thanks for the support Kmanator

    Dogs bark and caravan goes!

    Nevertheless, I will continue on the path I have chosen.

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    I see now that you are finnish so probably this Will be crazy and great, i take all i said back

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    A Honda CB750 scrambler! Also ill advised.
    The Honda CB750 frames were only 1/16" thick or .062 thousandths.

    Most aftermarket frames are .120 thousandths thick. The diameter is usually bigger too.

    Why not make that 500 Suzuki into a cafe bike?
    Last edited by Luky; 02-07-2019 at 1:33 PM.

  10. #10

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    Ignore the naysayers and stick with it!
    I've seen a number of GS500 projects that have looked really good when done, although (as yet) not one with the same sort of off-road bias as yours will have.

  11. #11

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    I've seen this crazy person ride the piss out of this bike on the dirt track, I think he's crazy enough to actually pull this off. I'll be watching for sure! Good luck!

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    The frame is "clunky" because it's well designed rather than being a shrine to obsolete technology. Go for it and see what you get. It's not a collector machine so there's no resale value to damage. Have fun and post pics.

    BTW have a look at "street fighter" style customs. They make practical use of modern donor motorcycles and have some good ideas to do it cheap.

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    Click image for larger version. 

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    Little by little it begins to look like what I have planned.

    BTW the frame is made of steel, so that's why it's easy to edit but i can also customize the aluminum frame, i have aluminum welding tools also.

    As said, work hampers hobby

    I'll update more photos of the project as I have time to do it.

    Cheers

  14. #14
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    Quote Originally Posted by BobberFreak View Post
    Click image for larger version. 

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    Little by little it begins to look like what I have planned.

    BTW the frame is made of steel, so that's why it's easy to edit but i can also customize the aluminum frame, i have aluminum welding tools also.

    As said, work hampers hobby

    I'll update more photos of the project as I have time to do it.

    Cheers
    Aluminum that has been anodized is a special welding consideration.
    Also welding aluminum leaves the parent metal at only 65% of the total strength after welding.

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    I did Something.
    E.g. I made a side covers of 1mm sheet metal.
    Shaping metal with hammer against the plywood mold and "da daa" it´s ready. Quite easy job.

    Ou shi*. Snow has melted and motorbiking season is approaching.
    But, the roads are full of sanding sand so no hurry to drive, can be a bit dangerous.

  16. #16
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    Quote Originally Posted by BobberFreak View Post
    Click image for larger version. 

Name:	20190218_200758.jpg 
Views:	9 
Size:	292.3 KB 
ID:	91233

    Little by little it begins to look like what I have planned.

    BTW the frame is made of steel, so that's why it's easy to edit but i can also customize the aluminum frame, i have aluminum welding tools also.

    As said, work hampers hobby

    I'll update more photos of the project as I have time to do it.

    Cheers
    Welding on that aluminum frame.
    Remember that the aluminum frame has been anodized, This can cause a problem welding it.
    Also when welding the aluminum, the weld will only be 64% strength of the parent metal.
    Since you do not know what kind of aluminum you have then you will have to call the manufacturer or use 4043 welding filler material. Either way it is problematic.

  17. #17
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    The side panel looks very good!

  18. #18
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    The exhaust will look like this.
    Something color it needs, no chrome, maybe white.
    Well, let's see what happen.

  19. #19

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    Interesting build , cool idea

  20. #20
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    Hi.
    Sorry that I haven't remembered updating this project much. Many projects at work
    Right now, Scrambler looks like this.
    Click image for larger version. 

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    A lot has happened since the last update.
    E.g, the bottom of the tank must be shaped to fit between the body tubes. The tank is from a Honda cb 350.
    I am currently working on a hippie chopper so the scrambler will finished later.

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