BOOOMMM... let the project begin

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BOOOMMM... let the project begin

Post  stax on Mon 19 Jul - 19:28

Today i finally started with my project!
My Suzuki GS 450 E will be transformed into a caferacer.
I have a vision in my mind and i try to be as budget friendly as i can.
No hurry with this project because i don't have any experience with building a bike whatsoever!

And now some pics because i know you like them the most afro

The Beginning:


Halfway:


End of Day 1:


It didn't go as smooth as i liked.
I have some troubles but i'm sure i'll manage Twisted Evil

stax
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Re: BOOOMMM... let the project begin

Post  kornfed on Mon 19 Jul - 19:37

you're almost there Wink
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Re: BOOOMMM... let the project begin

Post  stax on Mon 19 Jul - 19:55

kornfed wrote:you're almost there Wink

I wish Very Happy

I'm going i'm going to powdercoat the frame and wheels.
Have to rebuild the electric system.
Engine needs a paintjob but it runs smooth and has already been checked.

My biggest problem at the moment is this:



Shocked ... How can i remove that bold without destroying my cylinder?

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Re: BOOOMMM... let the project begin

Post  Toecutter on Mon 19 Jul - 20:19

weld a little steel bar to it with two welding points and screw it out ! with the TIG ? welder

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Bolt remover

Post  desautdw on Mon 19 Jul - 20:27

Drill a small hole in the center of the bolt shaft and use an easy-out (reverse thread screw) that threads in the removing position. That then gives you something to turn and it bites into the shaft as you turn counter-closkwise. Also some thread lubricant beforehand.
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More on removing broken bolt

Post  desautdw on Mon 19 Jul - 20:30

Once you remove the exhaust pipe and flange, it will give you more working room. You might even have enough of the bolt shaft exposed to put some vice grip pliers on it, but soak it good in thread loosener first.
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Re: BOOOMMM... let the project begin

Post  Toecutter on Mon 19 Jul - 20:46

desautdw wrote:Drill a small hole in the center of the bolt shaft and use an easy-out (reverse thread screw) that threads in the removing position. That then gives you something to turn and it bites into the shaft as you turn counter-closkwise. Also some thread lubricant beforehand.

This sounds more reliable and more professional!!

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Re: BOOOMMM... let the project begin

Post  Gss on Mon 19 Jul - 23:40

And if the above dusnt work you can always use a Heli-coil.

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Re: BOOOMMM... let the project begin

Post  stax on Mon 19 Jul - 23:53

desautdw wrote:Once you remove the exhaust pipe and flange, it will give you more working room. You might even have enough of the bolt shaft exposed to put some vice grip pliers on it, but soak it good in thread loosener first.



Thx!! This helped!
I removed the exhaust and tomorrow i'm going to remove the bolt shaft with grip pliers.
Don't have one at the moment

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Another helpful hint

Post  desautdw on Tue 20 Jul - 16:38

After removing the parts and soaking it with lubricant, you may want to grind or file down the sides of the bolt to make it more flat on the sides and give you a better grip with pliers or wrench. Good luck!
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Re: BOOOMMM... let the project begin

Post  stax on Tue 20 Jul - 18:52

Some progress...




Hopefully i'll have just the frame tomorrow so that can be prepared for powdercoating.

Thx for all the usefull tips guys!

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Re: BOOOMMM... let the project begin

Post  stax on Wed 21 Jul - 20:11

Some progress:



Now i need to figure out how to remove the headset (balhoofd)
What kind of tools do i need for that?

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Removing Triple Tree

Post  desautdw on Wed 21 Jul - 23:41

I guess you are refering to the triple tree mounted in the steering stem. Remove the pinch bolts, wedge a screw driver in the gap. To actually pull off the top of the triple tree you need a BAW (Big Ass Wrench) with an extension or breaker bar over the end to give you lots of leverage.
Again, some penetrating oil may help around the bolts and head bolt. Need to use the correct size wrench or you can damage the head bolt. I have been known to lay the whole frame on it's side and jump on the breaker bar attached to the wrench to get it to pop loose. A small sledge hammer to your breaker/extension bar may also do the trick.
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Re: BOOOMMM... let the project begin

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