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old fart
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3,716 Posts
Discussion Starter · #1 ·
made a decision to build a retro style bike along the lines of a GS550E Suzuki i had as a lad.
it would be a ground up build out of suitable parts and assembly's i could source from the likes of E-bay, other forums
and mates.
making anything that i couldnt beg, borrow or steal along the way :)

had seen someone doing much the same thing on a forum i use, i asked the guy if he
didnt mind if i copied some of his ideas, was glad to help.

i have started with a GS750 frame and 1200 bandit motor.

Parts i have up till now..........

Engine......................£400 (inc carbs, filters, coils)
Frame......................£120
Swing arm................£75 (inc torque arm & chain guard)
Spindle.....................£30 (inc caliper hanger & wheel spacers)
Rear wheel...............£65 (inc sprocket carrier & disc)
Forks.......................£294 (now replaced with different items)
Rear caliper..............£50
Oil cooler.................£30 (now replaced with better item)
Seat........................£70 (now replaced with better item)
rear fender..............£14
GS lower triple .......£14 (not now being used)
CBR lower triple......£50
Front wheel spindle £15
Front calipers.........£26
tail unit/rear light....£53
GS battery tray......£16
exhaust, bars, clutch/brake M/C's, switch gears £170 (Exhaust now replaced with better item)
GSX1400 swing arm spindle..............................£5
CBR1000RR 07 front wheel.....£0 (from my CB893RR build)
CBR1000RR lower triple & wheel spindle ............£60
GS750 tank x2 £250
CBR1000rr 08 rear M/c £15
GS swing arm spindle £20
head bearings £20
CBR1000rr 07 top yoke £60
Bandit 12 harness & CDI £55
GSX1400 Shocks £70
GS tank rubbers £15
GS750 side panels £27
Yoshimura steering stem nut :) £14
Rear sets £80
Passenger pegs £15
Seat lock £15
Front Discs £100
Alloy block for jack up plates £20
S/steel bar for exhaust adapters £50
handle bar risers £10
s/steel seat hinge pins £5
RS38 Carbs £500
Akarapovic s/steel full system £740
Ignition lock £35
rear disc bolts £15
caliper hanger bolts £10
rear sprocket nuts £12
rear spindle nut £22
CRG clutch lever £45
Translogic dash £450
19 row oil cooler £35
Giuliari seat £110
oil cooler fittings/hoses £300
clutch hose £23
brake pressure inline switch £8
H/light £70
H/light mounting bracket £35
Ti rear brake bolts £20
Powder coating so far £250
PJ1 engine paint £40
production certificate for frame from Suzuki UK £95
wheel bearings & seals £35
GSXR600 stick coils £30
replacement cam cover £12
Engine cover gasket set £20
rear light bulb holder £6
rear light brackets £15
various Ti & S/steel nuts, bolts & fastners ££££££££
various shrink wrap/spiral wire cover ££££££££
Battery £53.50
EBC HH front brake pads £43
Paint work £400 (big thanks to Arnie at Pro Kustom paint)
beer for machinist £lots
MSVA test (vehicle registration & road worthiness) £95 (still to book)
insurance (not even thought about it yet)
frame welding £80
Road tax £80 ish (when i do it)
R&G indicators £120
LED indy relay £12
mirrors £18
CBR600RR coil loom £12
BFT billot alloy engine cover £100




finished bike...............................priceless :)


FUCK ME this is getting expensive!!!! better not let the wife know.................................................................HAha fuck her :fu:
 

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old fart
Joined
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3,716 Posts
Discussion Starter · #2 ·
I havent started actually doing any work yet, as i was waiting to get the
engine, swing arm and frame before attempting any spanner work!
collected the engine yesterday, it has twin Pod filters and jet kit fitted, guy i got it from said the guy that built it had fitted a "Race Cam", we will have to wait and see :)
Frame was sat outside my back door when i got home from work tonight, so just
awaiting the swing arm before DW
might spend a little bit of time later this evening taking the engine out of the frame members that are still bolted around it.
will get a pic of engine and frame with a "proof of date" later too :party-smiley:
 

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old fart
Joined
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3,716 Posts
Discussion Starter · #3 ·
went to work removing the engine from what was left of the main frame! came out quite easily, now
i just have a collection of bits building up in the middle of the shed waiting for the swing arm to arrive.

when i am happy to make a start i will take a pic of a newspaper with all the bits to give the time line, not
going to start to put things together till then


 

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old fart
Joined
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3,716 Posts
Discussion Starter · #4 ·
rear swing arm and seat came today :party-smiley:
so wont be long before i start to DW,
wont be for a couple of days at least though, as i am off on the ranges with the mortars until the end of the week :oops: got to make a living some how to pay for all the bits :)
made an offer on a tank today :rock:
 

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old fart
Joined
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3,716 Posts
Discussion Starter · #6 ·
Got the new forks today, they are almost new, just a hint of dirt from the brake pads, no marks!!!!!!! I am well pleased
might just fit them to my street fighter hornet, and put the 07 forks off that onto this build
other bits and pieces turned up as well, GS rear mud guard, battery box & lower yoke. GSX1400 rear caliper, getting a right pile of parts together now :rock: might just get round to starting the build soon :)
collecting the exhaust system, bars with M/c's, switch gears and throttle on Sunday.
still waiting for the bits from the States, probably spend a few days or so in customes befor i get anywhere near them!
having a bit of a problem with the guy that i won the tank off :oops: i have messaged him twice for a combined postage-payment invoice but have had no reply for three days now!!!!! only took him 5 mins to answer my "offer" FFS.
 

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old fart
Joined
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3,716 Posts
Discussion Starter · #8 ·
here we go then................Build ON

Picture of paper with date



paper on pile of bits



cut the rear footpeg hangers off, cut the side stand bracket off, assembled the rear swing arm with wheel and caliper and lined things up.
then did a test fit of the fork spindle to see what the front will fit like. going to see if i can get some ball races to fit the honda spindle and GS frame so i wont have to swap spindles around, only one way to find out.
sorry about the "fog" but that was the result of all the cutting with the angle grinder


 

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old fart
Joined
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3,716 Posts
Discussion Starter · #9 ·
got home from work and went straight to work on fitting the swing arm, chain run is going to be tight to the frame by the look of things, but might be able to machine some metal off the sprocket carrier to move it over a bit if needed.
wheel will be nice and central, but will have to get some spacers made as the ones that came with the wheel (hyabusa) are not quite right, not a biggy.



 

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old fart
Joined
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3,716 Posts
Discussion Starter · #10 ·
tonight's fun revolved around man handling the engine into the frame by myself, got it in after a bit of huffing and puffing, fitted a bolt to the lower engine mount to hold it all in place, then played around with sliding it from side to side until i was happy with the chain run and the exhaust clearance.
the chain is about 3mm off the frame tube! but dont think that is going to cause any big problems.
the far left exhaust down pipe is also very close to the frame member, but think that will be easily sorted when i get the bike down to Zorstec to get the rear pipe made and fitted.
happy with how it is now sitting, so i will start to make some mounting brackets to get it held in properly without moving.
thats enough for tonight, so going to sit and have a couple of tins after a productive evenings graft :rock:





 

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old fart
Joined
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3,716 Posts
Discussion Starter · #11 ·
started to fix the engine in place, first made and fitted some spacers to the rear lower
engine mount.



then found some alloy plate to make the front engine mounts, only had enough to make the one for now, so drilled the holes and mounted it, will trim it down and shape it later.



how it now sits with the rear jacked up to where it will sit whith the shocks on






checked the forks off my other bike for fit with yoke and wheel, all looks good

 

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old fart
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3,716 Posts
Discussion Starter · #12 ·
found some more alloy off cuts at work this morning, so will be able to crack on with the engine mounting plates tonight hopefully, also brought the front sprocket cover and clutch slave cylinder to work with me, gave it a run through the de greasing bath, now all is good.
will putt it all back together tonight with a good aplication of Red rubber grease on the seal.
 

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old fart
Joined
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3,716 Posts
Discussion Starter · #14 ·
didnt manage to get much done this time, i spent a fair bit of time measuring bits for my mate to make me on his lathe, wheel spacers, swing arm bush and disc spacers.
then came up with the idea of having a removable rear top engine mounting bar, so it will make removal and re insertion of the engine a lot easier.
i have removed the cross bar from the remains of the bandit frame, i will get some threaded plates welded onto the ends so it will bolt into the frame from both sides.
it will hopefully also act as a frame strengthener.
here it is bolted to the engine where i want it to sit in the frame.


 

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old fart
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3,716 Posts
Discussion Starter · #16 ·
cleaned up and shortened the bolts for the front engine mounting plates




then made a mounting plate for the mid engine fitment




then worked on cleaning up the rear mounting and getting it ready for making some plates to get welded to it, will have to find some plate from work tomorrow.



then just had a play fitting the tail, seat, battery box and mud guard



 

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old fart
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3,716 Posts
Discussion Starter · #17 ·
had a quick look over the carbs yesterday, well all i can say is some people are total fuckwits!!!! on two of the carbs the rubber vacuum hood on top of the carb slide was trapped/pinched under the top cover :nuts:
from what i can see the hoods are not holed, but must have been restricting the movement of the slide when in operation.
the K&N twin pod filters were attached on the outside carbs with metal jubilee clips, but were held on the insides with ZIP ties FFS :wtf:
when i tipped the engine forward to work on the mounts some oil seeped from the cam cover! when i looked closer it was from the cam cover bolt seals, they must have given up with old age and had been "sealed" with silicon sealant, think i will have to give the motor a good going over before i think of starting it up for real.
on a good point though, it has got a Dynojet kit fitted :rock: not sure of the stage until i open the carb bottoms up.
Oh back on the fuckwit trail, found that when they removed the harness they had just cut the throttle position censer connector off!!!!!!!! nothing like doing things the quick way now is there?
got some steel plate from work today, so might make some plates for the engine rear mounting bar later :)
 

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old fart
Joined
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3,716 Posts
Discussion Starter · #19 ·
Played around last night and realised that with the rear engine mount as low as i had it fitted it would get in the way of the chain!! so i did a bit of re arranging and made some different plates, now think i have it sorted.
today got the swing arm spindle and front calipers, really happy with the calipers for £27, not fucking happy with the VAT cost of almost £10 from customs FFS!! wankers
spent tonight giving the calipers a clean in my de greaser and a wipe down.
waiting for the bits back from my mate so i can DW
 

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old fart
Joined
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3,716 Posts
Discussion Starter · #20 ·
got the bits back from my mate, so fitted the swing arm spacer bush to the swing arm and got the arm fitted with the GS spindle.




then fitted the rear wheel with the newly made wheel spacer,





all looked good, used a straight piece of flat bar to check the sprocket alignment.



not sure of the length of shock needed, but with it set the way it is in the pic, a 400mm shock will do, but might just need one shorter at 340mm.
with either the chain will be a clear run over the top of the swing arm.
 
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