gs550 7k miles cafe racer build

[carbonmoto]

We have now started another build, a 7k miles gs550 that's been in storage for most of its life.After cleaning the bike it is obvious that it is in very good condition no rust on the frame at all so its a good base for a cafe racer.
[img src="[/img]i16.servimg.com/u/f16/17/12/80/38/gs55011.jpg"]
We have quite a few gs550 5 or 6 ish so the idea is that we make this bike into a kit that can be bought to convert the 550 & 750 into a cafe racer with everything documented in the instructions, all fittings brackets etc included, this will be the test mule so to speak.
We are making a completely new seat for this bike,starting with foam & covering it with body filler with lots of saning to get the shape, my lad has put something like 15 hours into this already, then we can make a mould or 2 & knock some seats out,The look im wanting is similar to the next picture (nothing fits properly as we have to de lug the frame & make a new base for the manx norton tank to fit the gs frame then it will sit properly.
This one might even have a fairing

[dungbug]

I'll be keeping an eye on this thread based on your last build.

[carbonmoto]

Got loads done on this & the other 2 bikes im building.
This one will be known as gs550 7k miles
The other gs550 will be known as gs550 #2
& a gs1000 g shaftie i hate shaft drive
Will make new threads for each bike
So here is what i have done on this bike.
Totally stripped it to rolling chassis, cut off all brackets that are not needed ie side panel, battery box, foot peg mountings

Not a lot left now.
Just collected a couple of swinging arms i have had modified by my lads mate,
gsxr600/750 alloy arms with twin shock mountings now welded on
The seat plug & mould made & a seat has come out of the mould ,looks good with the tank
will start the dry build tomorrow

[carbonmoto]

Had a change of plan for this bike, it wont be using the ally swinging arm.it will be all standard running gear with the standard cast ally wheels.
The body work will be a Rickman tank, Rickman /Avon type fairing with one of our new design seats.
Just got the foot peg hanger brackets, fairing mount bracket & the seat mounting brackts to weld on the the frame gets blasted & can then go for powder coating,just plain gloss black, hopefully next week.
This is a rough idea of the look (the fairing is just sat on the fork tops)
ANY SUGGESTIONS ON COLOUR as im not decided on this one yet

[carbonmoto]

just a quick update
the frame is all welded up, brackets removed & smoothed off, it has now gone for blasting & powder coating (yes im not painting this frame).
Will post pictures of it when it comes back.
have been getting on with the engine, cleaning it up ready for painting, all side cases off it now to be polished next week

[dungbug]

Fast work What colour did you decide on?

[carbonmoto]

well as we are going for a rickman type look the frame is having a titanium colour powder coat ( it actually looks similar to the nickle finish used on the original bikes)
The body work is still a bit up in the air at the moment, will be a dark colour possibly black
with a twist!!!

[carbonmoto]

Sorry for the lack of posts recently - we are extremely busy at the moment, work has been getting done but just not had a minute to post.
The frame , swinging arm, brackets etc have come back from the powder coaters - a company i have not used before but a mate recommended them, i can only say wow Excellent finish done quickly at very good prices by really nice people who do ring you when its done (try them Metal magic @ barnsley s.yorks)

The colour is called titanium looks like a nickle finish.
The parts are coming together well, all bearings have arrived, just fitted swinging arm ones,just waiting for a big delivery of stainless fasteners then the assembly can begin.
also made a new seat unit for this bike & the mould is ready to make seats
more next week as it could progress quite quickly, should get the engine in during the week (hopefully)

[TerraRoot]

did that cost much? many things could be shinyed up.

[dungbug]

Finish looks bloody good!

[stevencakes]

very nice looking forward to the finished product love gs's and a fan of cafe racer look so a winning combination in my book.

[carbonmoto]

Thanks for the comments
TerraRoot - can remember exact cost as i had a lot of bits done but was around £110 for frame, swinging arm,torque are, side stand & yokes blasted & powder coated took just over a week too
they will be getting all my work & quite a few of my local customers are now going over to them.
Dung bug - looks even better in the flesh
Steven cakes - me too we have about 10 gs's waiting to be cafe'd we like to put gsxr lumps in them too!!

[carbonmoto]

Got a bit more done on this & the other gs550.
The engine is in, but still waiting for a couple of new mounting bolts to turn up along with the swinging arm nut in stainless.
Polished casings now on with new stainless allen bolts.
New head stock & swinging arm bearings fitted.
Next job is to polish the fork legs & put new seals in them & then on with making the body work,seat,tank,fairing,mudguard & chain guard all in carbon fibre.
Waiting for the wheel rims to be de chromed then to be powder coated & rebuilt.