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I designed a new top yoke which I had waterjet cut from 20mm aluminium plate. Unfortunately I made an error in assuming the geometry is the same as the GT500 yoke...it isn't, so the first one was wrong, doh ![*]
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Next was the task of the keg style 2 stroke tank, which would hang from the newly welded frame cross member. Filling by a small side spout, with a beautiful little threaded knurled top.[*]
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I wanted flat bars on this bike, so I used a set of really nice risers that were on a wrecked Yam custom that we had in the work shop.[*]
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Polishing is a tiresome task, and as our local polisher also does plating....I sent all the not so shiny stuff to him. I take the precaution of picturing all the bits, just in case something goes missing.[*]
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In a quest to create a stripped down tidy looking custom, I wanted to move the battery and electrics into the seat void, which means making a tray up to suit.[*]
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The front edge of the glass seat unit was contoured to match the tank.[*]
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I matched a piece of ali plate to the seat and tank as well, to mount the seat cushion to.[*]
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Cleaning, polishing and refurbishing the switch blocks is very fiddly, but worth it.[*]
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Back to the seat.....most of the loom was replaced, and some sections needed extending to get the reg/rec under the seat.[*]
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I made a simple tongue to bolt on the frame, and a catcher on the seat unit....this way there are no visible bolts at the front at least.[*]
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I shaped a strap for the mount at the rear of the seat, and used plenty of bond to secure it.[*]
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This is the plate that would carry the seat cushion. It's bolted to the seat unit using riv-nuts.[*]
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Naturally, a set of our own rearsets were fitted. Slightly changed on the gear side, as both pipes were to be on the right.[*]
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The front end starts to come together....a handy little tip....the tops of the legs are usually tatty from being under the ears for 40 years. I simply covered them with some polished stainless tube, and no-one would ever know. After market head lamp brackets were to carry an upgraded headlamp from a modern GS500.[*]
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In the meantime, the seat upholstery was done, and the paintwork completed. Suzuki Maui blue no longer available, but Daihatsu Peacock blue is a perfect match ![*]
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The motor was good mechanically, but was wearing 37 years of grime and shite, so I sealed up the ports, and had it soda blasted in one lump.[*]
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Back to the water jet cutters, after designing a clock mount, and a front fender stay. These would be bent and folded, then polished.[*]
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The 2 M6 holes in the new clock mount, are for a pair of LED's for the neutral and high beam indicators.[*]
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One of the best days of the build.....getting the body work back from my pal Pete.....lovely ![*]
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