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Old 02-15-2015, 09:46 AM   #1
RustyStuff OP
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Joined: Jan 2012
Location: Crakima,Wa
Oddometer: 808
My GS450Adventurer

It's been my sport bike for the last 3 year's. I've decided to take it down a different path this year, a much dirtier one.

The plan-
Braced Bars( Done)
Hand guards( On order)
MX Pegs(DR650 ordered )
Folding shift lever( DR?)
H4 headlight with rock shield( Done)
High fender mod( Done)
Skid Plate and Crash bars
Small 1/4 fairing.
Volt meter and Phone charger

TrailWing TW39/TW40 tires( most aggressive tires that will fit the rear rim)

My phone was stolen Friday, so I'm missing some pictures from the start of the process.

I cut the stock fender down, removed the fork brace and built a aluminum fender mount/brace.




Rear mount's
[l]





CADing the skid plate-


The Best alloy of aluminum- OldRoadsignium.



Top Mount.


Mounting bar/Brace.


All buffed up-
l]

The Brace/Mounting Bar give's the oil filter some serious impact protection.
]

]



I'm going to rivet a 2nd layer on the bottom half and build the rear mounts today. Then i'll drill holes in it for more airflow and mount it up.
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Old 02-15-2015, 09:59 AM   #2
theraymondguy
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Location: Niagara, ON
Oddometer: 158
That's a KLR grade road sign skid plate.
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Old 02-15-2015, 10:09 AM   #3
RustyStuff OP
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Location: Crakima,Wa
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Quote:
Originally Posted by theraymondguy View Post
That's a KLR grade road sign skid plate.
Thank you.

New Grips, "rally raid" style.



I think I'll put these badges on it.


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Old 02-16-2015, 05:39 AM   #4
emti
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Joined: Aug 2010
Location: northern n.y.
Oddometer: 262
That's nice, I rode one for 14 years, They are a tough bike. You might as well take off the turn signals now. What are the badges from? emti
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Old 02-16-2015, 07:17 PM   #5
RustyStuff OP
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Quote:
Originally Posted by emti View Post
That's nice, I rode one for 14 years, They are a tough bike. You might as well take off the turn signals now. What are the badges from? emti
Badges are from a Late 70's Dodge truck.

Once I get the hand guards I'm thinking of moving the turn signals up there( set of orange marker lights?).
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Old 02-17-2015, 07:20 PM   #6
NortwestRider
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Location: 3.7 miles North of Hell...SEATTLE....
Oddometer: 3,996
I put those same badges on my last sidecar build.
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Old 02-18-2015, 09:24 PM   #7
RustyStuff OP
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Quote:
Originally Posted by NortwestRider View Post
I put those same badges on my last sidecar build.
Glad I'm not the only one.

Big day today. My hand guards showed up and and got to work fitting them.

Cheap ones off eBay, quality seems OK for the price, could have used more finish work, but if I'm chopping them up, I don't care.

Unboxing-




They came with this set of Larger deflectors-


Hmmm, Levers are too long.


Let's fix that-






Much better.


Did the same thing on the Brake side. Cut the lever, Cut the hand guard down 3" to fit, fiddled with the placement of the control's.



Both done-


Bolted the Aux deflectors on-






Mounted the skid plate up- Epoxy/Rivit's attach the 2nd layer to the sump area. Still need to make a back brace up and fit the Center stand skid.



[



Fun times.

I'm going to need a much shorter throttle cable, this one is way, way too long for this.
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Old 02-19-2015, 07:12 AM   #8
NortwestRider
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Location: 3.7 miles North of Hell...SEATTLE....
Oddometer: 3,996
I have hand guards on my GS500 adventure.





Live life,be yourself !!!!.
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1994 KTM440 exc
1983 IT490
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Old 02-19-2015, 03:41 PM   #9
RustyStuff OP
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What size is your rear tire? I'm envious if you can run 17-18" dual sport tires.


Should try and meet up some time in the spring to compare bikes.
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Old 02-19-2015, 05:31 PM   #10
NortwestRider
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Location: 3.7 miles North of Hell...SEATTLE....
Oddometer: 3,996
The rear is a 140/17 K60,stock was a 130.


Live life,be yourself !!!!.
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1994 KTM440 exc
1983 IT490
GS500ADV..THE PURPLE EXPLORE
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Old 02-19-2015, 10:36 PM   #11
RustyStuff OP
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Did a bit more this evening.

Threw the center stand skid on-





And then I did a bit of Cable/Hose/Wire rerouting, I want to keep it as tight to the bike as I can.


I really need to wash this thing, and I mean really scrub it down. I didn't realize just how nasty it's gotten. I ride it almost daily ( when it's warm enough) and washing takes a time I usually don't have.
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Old 02-20-2015, 10:48 PM   #12
RustyStuff OP
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Location: Crakima,Wa
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lAfter having the bike fall over a few times, I'm thinking fat-foot on the side stand.

So, I dig though my heap-o-garbage and find this rusty-crusty washer hanging out.



Hmm. '


Start the prep by useing the "antique" wire wheel/Buffer.



Onto the "precision work jig" inside my " Fireproof welding booth" AKA-a old BBQ.



Proceed to making the ugliest weld I've made in a while. Apparently there was oil inside the foot of the stand, because it blew-up in my face and caught fire.





Thank god no one will see this....



Mmm, Spray paint.


Back on the bike she goes.



Hopefully falling over is a forgotten worry.
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Old 02-21-2015, 05:36 PM   #13
snake89
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Location: Memphis, Tn. unfortunately
Oddometer: 135
I did this on a Kawasaki W650 before i traded it for a KLR. Made a damn good gravel and dirt road runner, lots of fun.
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Old 02-21-2015, 06:48 PM   #14
RustyStuff OP
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Location: Crakima,Wa
Oddometer: 808
Platform peg's came in today. Fun discovery, DR650 pegs are a direct fit into a GS.









Much more stable, I can see why everyone uses them.
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Old 02-22-2015, 09:45 AM   #15
NortwestRider
TRIPOD ADVENTURER !!
 
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Joined: May 2008
Location: 3.7 miles North of Hell...SEATTLE....
Oddometer: 3,996
My GS450Adventurer

Quote:
Originally Posted by RustyStuff View Post
Platform peg's came in today. Fun discovery, DR650 pegs are a direct fit into a GS.









Much more stable, I can see why everyone uses them.

DR650 pegs fit damn near everything !!!.
Haha
I had them on my Vstrom and currently have them on my NCx.


Live life,be yourself !!!!.
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2012 Honda NC700XAR
1994 KTM440 exc
1983 IT490
GS500ADV..THE PURPLE EXPLORE
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