GPz1100 Sport Utility Hack Build

Discussion in 'Hacks' started by Feedback Cycle, Jan 3, 2012.

  1. Feedback Cycle

    Feedback Cycle Been here awhile

    Joined:
    Nov 25, 2011
    Oddometer:
    101
    Location:
    Michigan
    Billtr96sn.
    I'm afraid many may find you comments careless. I don't want a flame war here.
    Many people build a sidecar because they have trouble holding up a motorcycle, etc. It is a scientific fact that exercise will not help many health conditions and life style changes have proven nearly impossible for most people so lets keep in on the hacks. We Cool? Cool? :freaky
  2. NortwestRider

    NortwestRider TRIPOD ADVENTURER !!

    Joined:
    May 25, 2008
    Oddometer:
    4,220
    Location:
    3.7 miles North of Hell...SEATTLE....
    Nope,I'm at the point in my life that I don't need to compermise.If it's uncomfortable to ride without steering aids then I will build what ever aid I need.It's all about enjoying my self and being comfortable!!!.
  3. val. h.

    val. h. On the wrong planet

    Joined:
    Nov 14, 2007
    Oddometer:
    123
    Location:
    UK. North Wilts'ish


    Hmm, It'd be intersting to compare the two, see what the real difference is. I'm not far from you either. Up the road in Wiltshire.


    Val.
  4. Feedback Cycle

    Feedback Cycle Been here awhile

    Joined:
    Nov 25, 2011
    Oddometer:
    101
    Location:
    Michigan
    It would be great to have a hack swap meetup.
    We would all take turns riding each others hack from stop to stop.
    Then decide the best setup. :clap

    Unfortunately, I have no plans to travel so far. Not on my hack anyway. It is set up poorly :rofl
  5. Billtr96sn

    Billtr96sn Flange Furtler

    Joined:
    Nov 15, 2010
    Oddometer:
    393
    Location:
    Somerset, UK
    That was the exact reason I put the chair on mine, I could get on it but not off :rofl so on with the 'chair' it was.

    Val.h. I would love a meet up and compare. You dont get many opportunities for that. I am in Chard,South Somerset.

    I wasn't meaning to be abrasive before and am sorry if I came across that way.
  6. Feedback Cycle

    Feedback Cycle Been here awhile

    Joined:
    Nov 25, 2011
    Oddometer:
    101
    Location:
    Michigan
    Not building much. Did a little riding. Always evolving the design as the days go by.
    I've been fleshing out the fender slash seat? Yep. I said seat.
    I just can't get over having a HUGE hauling space. I do plan on having a removable seat for regular riders, but I want to have a racier bench seat built in for any friends that want to ride side saddle for a short jaunt. Thy can fly high like they are riding a Hobie Cat in corners :rofl I'm thinking I will have a long row padded seating within the square frame above the tire. :wink: Then, a lot of tie downs mounts and grab rails EVERYWHERE.

    <a href="http://s1095.photobucket.com/albums/i466/168912/0020/?action=view&amp;current=P2200017.jpg" target="_blank"><img src="http://i1095.photobucket.com/albums/i466/168912/0020/P2200017.jpg" border="0" alt="Photobucket"></a>

    <a href="http://s1095.photobucket.com/albums/i466/168912/0020/?action=view&amp;current=P2200022.jpg" target="_blank"><img src="http://i1095.photobucket.com/albums/i466/168912/0020/P2200022.jpg" border="0" alt="Photobucket"></a>

    <a href="http://s1095.photobucket.com/albums/i466/168912/0020/?action=view&amp;current=P2200020.jpg" target="_blank"><img src="http://i1095.photobucket.com/albums/i466/168912/0020/P2200020.jpg" border="0" alt="Photobucket"></a>

    <a href="http://s1095.photobucket.com/albums/i466/168912/0020/?action=view&amp;current=P2200025.jpg" target="_blank"><img src="http://i1095.photobucket.com/albums/i466/168912/0020/P2200025.jpg" border="0" alt="Photobucket"></a>

    So visualize this, frame painted very dark grey/blue. Black accents. Red panels on the front.
    Black anti-skid rubber on the deck (possibly wrapping around the fat pipes.) Some lights for the rally look. A aluminum removable storage box.

    BTW, do you see my crazy floor welds! Bha!. First I had a few rivets to hold the sheet metal. Thy broke, Added a couple tack welds. Broke. Few More. Had a mess. Finally I welded all the way around just so it would stay put. The pipe was big and the metal was thin. Now it is crazy ugly. Well kind of cool.

    That's where my heads at.
  7. Feedback Cycle

    Feedback Cycle Been here awhile

    Joined:
    Nov 25, 2011
    Oddometer:
    101
    Location:
    Michigan
    It's been a while since I could make an update. Changed the oil. Chased down a warning light on the dash.
    Dang, I have regular bike maintenance to take care of besides the hack stuff.


    First, I have been thinking about grab handles. I want the rider to get a hold of something. I was looking to some of the racing and enduro sidecars for inspiration. I bought some hollow tube to bend but it kinked too often. I stepped up to som 1/2" solid bar. It has wonderful feel but.... I couldn'nt weld it to my tube without burning holes everywhere. It was too thick for my welder. Finally, I had a thought, I would weld them to thicker metal and attach the handles with bolts.:wink:

    <a href="http://s1095.photobucket.com/albums/i466/168912/0021/?action=view&amp;current=P1010020.jpg" target="_blank"><img src="http://i1095.photobucket.com/albums/i466/168912/0021/P1010020.jpg" border="0" alt="Photobucket"></a>

    I also had trouble getting considtent bends a/or making the radius small enough. So, I finally just used a long bar and a hole on my hitch receiver and bent a bunch of bars.

    <a href="http://s1095.photobucket.com/albums/i466/168912/0021/?action=view&amp;current=P1010025.jpg" target="_blank"><img src="http://i1095.photobucket.com/albums/i466/168912/0021/P1010025.jpg" border="0" alt="Photobucket"></a>

    I used angle iron of all the bases because I had it. :evil Also, It gives the handle a couple places to contact the tube. I use an angled bold to tighten it down. My current bolts are temporary. My final ones will be larger and more resolved. Sure. I have a lot on there now, some may be moved or removed as needed. The holes are all 4" apart so I can swap the handles. Also, since they are drilled at a 45 degree, I can put the handle on pointing up or down.

    I added some tabs around the base for tie downs. The tube is too large for me straps. This should help.

    I bought a used pickup bed liner mat from Craigs List for $40. I cut it to fit. Not perfect but pretty nice. I consider a basic mat but decided I liked the heavy weight and pliability of a truck mat. Also, it has the raised bumps on the bottom that allow it to dry. I also like the longe stripes. It looks well used but I like the fact that it blends with the 'patina' on my bike.
    I put a small piece on the seat/fender but expect it to actually be a seat more similar to my bike seat. Just thinking.

    <a href="http://s1095.photobucket.com/albums/i466/168912/0021/?action=view&amp;current=P1010022.jpg" target="_blank"><img src="http://i1095.photobucket.com/albums/i466/168912/0021/P1010022.jpg" border="0" alt="Photobucket"></a>

    I found this 2 gallon container for $2 at a garage sale. Weird? Anyhow, i considered using it as a fuel cell, or cutting it open and using it as storage in the front. It just looks cool. Maybe hold my tie straps.

    <a href="http://s1095.photobucket.com/albums/i466/168912/0021/?action=view&amp;current=P1010021.jpg" target="_blank"><img src="http://i1095.photobucket.com/albums/i466/168912/0021/P1010021.jpg" border="0" alt="Photobucket"></a>

    Finally, I have been working with some panels for the front. At first I was going to cut them large and use some nice little ss screws. But, ther are so many issues that I considered screwing them from the inside. Then I decided to cut them to fit in the very middle. Maybe weld on some tabs. Hmmm. I am not sold on anything yet.

    I've really decided to quit sweating the small stuff. This will never be polished. I want to be able to used it, break it, fix it. Evolve it. I plan to paint it with a brush.
  8. NortwestRider

    NortwestRider TRIPOD ADVENTURER !!

    Joined:
    May 25, 2008
    Oddometer:
    4,220
    Location:
    3.7 miles North of Hell...SEATTLE....
    I know how ya feel,everytime I sit next to the rig I see soooo many things to do that I don't seem to make much progress.Today I decided to just
    GET IT ROAD READY!!.


    Sent from my iPhone using Tapatalk
  9. Pete-NZ

    Pete-NZ Been here awhile

    Joined:
    May 8, 2011
    Oddometer:
    798
    Starting to look good... I like that style:clap...
  10. Feedback Cycle

    Feedback Cycle Been here awhile

    Joined:
    Nov 25, 2011
    Oddometer:
    101
    Location:
    Michigan
    Thanks! Wouldn't want to let you guys down :rofl
    My family looks at some of my additions and are just plain puzzled. They have never seen photos of enduro or racing sidecars. "Handles? Whay would anyone need handles?" :lol3 "Is this safe?" "No. Why would I want a safe motorcycle?"

    I started painting the frame last night. I was just 'testing' a little part. Then I 'tested' the whole darn thing.
    It is starting to blossom rust from sitting so long without protection. I still have welding to do but I can always grind off a little paint here and there. I skipped the spray and went for a brush and roller. Nice and thick. I decided that the floor and structure can have a industrial finish while the parts that have a high level of human contact will have a nicer finish. It seemed too fussy to make the frame as polished. And let's face it. My attention span is far to short to grind every weld and prep it right. I will post pictures soon.
  11. Feedback Cycle

    Feedback Cycle Been here awhile

    Joined:
    Nov 25, 2011
    Oddometer:
    101
    Location:
    Michigan
    I had to take a step backward and finalize my sub frames. There were things I needed to resolve.

    On the front, I removed all the weak U bolts and replaced them with an all bolt design.

    <a href="http://s1095.photobucket.com/albums/i466/168912/0022/?action=view&amp;current=P1010007.jpg" target="_blank"><img src="http://i1095.photobucket.com/albums/i466/168912/0022/P1010007.jpg" border="0" alt="Photobucket"></a>

    I also, removed some excess metal and added gussets everywhere.

    <a href="http://s1095.photobucket.com/albums/i466/168912/0022/?action=view&amp;current=P1010005.jpg" target="_blank"><img src="http://i1095.photobucket.com/albums/i466/168912/0022/P1010005.jpg" border="0" alt="Photobucket"></a>

    <a href="http://s1095.photobucket.com/albums/i466/168912/0022/?action=view&amp;current=P1010009.jpg" target="_blank"><img src="http://i1095.photobucket.com/albums/i466/168912/0022/P1010009.jpg" border="0" alt="Photobucket"></a>

    Painted black and whola!

    <a href="http://s1095.photobucket.com/albums/i466/168912/0022/?action=view&amp;current=P1010010.jpg" target="_blank"><img src="http://i1095.photobucket.com/albums/i466/168912/0022/P1010010.jpg" border="0" alt="Photobucket"></a>

    The bottom long bolts are bolted through the frame and the engine mounts. I feel confident they are strong.

    I created a plate that bolts to the opposite side of the frame and is connected with a massive3/4" hardened bolt and weld-in bung. Even if the smaller bolts shear, it cannot come free of the frame.

    I feel confident the front is solid.

    I've been working the rear sub frame. Almost done. Major improvements.
  12. cleatusj

    cleatusj Dirt floor engineer

    Joined:
    Dec 17, 2010
    Oddometer:
    1,253
    Location:
    Granbury, TX
    I like that a lot better, less chance of frame damage.
  13. Feedback Cycle

    Feedback Cycle Been here awhile

    Joined:
    Nov 25, 2011
    Oddometer:
    101
    Location:
    Michigan
    Agreed. I was worried the clamps would pinch my tubes.

    Rear sub frame updated.

    Again, I removed all C bolts. New bottom frame uses two hardened bolts into the frame(old centerstand holes)

    <a href="http://s1095.photobucket.com/albums/i466/168912/0022/?action=view&amp;current=P1010007-1.jpg" target="_blank"><img src="http://i1095.photobucket.com/albums/i466/168912/0022/P1010007-1.jpg" border="0" alt="Photobucket"></a>

    The entire upper part was redone. More accurate and nicer looking solution.

    <a href="http://s1095.photobucket.com/albums/i466/168912/0022/?action=view&amp;current=P1010001.jpg" target="_blank"><img src="http://i1095.photobucket.com/albums/i466/168912/0022/P1010001.jpg" border="0" alt="Photobucket"></a>

    You can see I added a few gussets here and there.

    A major change was the addition of two plates near the foot rest. Hardened bolts now pass through to the frame.

    <a href="http://s1095.photobucket.com/albums/i466/168912/0022/?action=view&amp;current=P1010005-1.jpg" target="_blank"><img src="http://i1095.photobucket.com/albums/i466/168912/0022/P1010005-1.jpg" border="0" alt="Photobucket"></a>

    It feel rock solid.

    Funny, I had it all covered when IO was tack welding but I still got residue on the metal near my footpegs. It however is only residue and wipes of. Whew!
  14. cleatusj

    cleatusj Dirt floor engineer

    Joined:
    Dec 17, 2010
    Oddometer:
    1,253
    Location:
    Granbury, TX
    Just proves we're only Good not God.
  15. Feedback Cycle

    Feedback Cycle Been here awhile

    Joined:
    Nov 25, 2011
    Oddometer:
    101
    Location:
    Michigan
    Yeah.

    Now back to the fun stuff. Hopefully I have removed the 'hebie jeebies' at speed.
    I will take it to a parking lot and do everything I can to break it.

    Now I need some storage... or maybe different bars? Different forks? Paint? Bodywork? Seats? Ballast? Fuel can? Lights? Graphics? Jeez have I got anything done at all?
    :huh
  16. Feedback Cycle

    Feedback Cycle Been here awhile

    Joined:
    Nov 25, 2011
    Oddometer:
    101
    Location:
    Michigan
    I've been experimenting. Cut a panel and pop-riveted it into place. I had plans to cut out shapes, paint them then use nuce square head stainless screws but it al required such a level of finish that I couldn't take it. So, this will just be painted. I actually want to de emphasize the rivets as the whold bomber home built look just seems over done. But it does add a nice texture.

    <a href="http://s1095.photobucket.com/albums/i466/168912/0022/?action=view&amp;current=P1010005-2.jpg" target="_blank"><img src="http://i1095.photobucket.com/albums/i466/168912/0022/P1010005-2.jpg" border="0" alt="Photobucket"></a>

    Next is my handlebar experiment. I added a simple support bar because I was getting flex when I really cranked on it.
    Also, I rammed a piece of steel into the left handlebar for more leverage. It helps but I am simply going to have to reduce the trail the proven ways. When riding, it's like hilding up a 1lb weight in your hands. No big deal but after 15 minutes, your whole body is aching. Combined with the snarl of the engine, this hack is just plain hyper and a little violent.

    <a href="http://s1095.photobucket.com/albums/i466/168912/0022/?action=view&amp;current=P1010009-1.jpg" target="_blank"><img src="http://i1095.photobucket.com/albums/i466/168912/0022/P1010009-1.jpg" border="0" alt="Photobucket"></a>

    Finally, I have started making a wire cover for the wheel/shock tower. I had always planned on covering the area but could never accept how much room I lost because of the pivot and mount points. Then I realized that I didn't really want to 'cover' it up, I just wanted to keep people from falling in. I plan to add more vertical rods so it looks like a square grid. It will bolt in place. I think it could look trick.
    :wink:
    <a href="http://s1095.photobucket.com/albums/i466/168912/0022/?action=view&amp;current=P1010007-2.jpg" target="_blank"><img src="http://i1095.photobucket.com/albums/i466/168912/0022/P1010007-2.jpg" border="0" alt="Photobucket"></a>
  17. NortwestRider

    NortwestRider TRIPOD ADVENTURER !!

    Joined:
    May 25, 2008
    Oddometer:
    4,220
    Location:
    3.7 miles North of Hell...SEATTLE....
    I took a bar end off a old mountain bike and bolted it the end of the left bar for leverage and a place to rest my hand on looooong straight CROWNED roads!.


    Sent from my iPhone using Tapatalk
  18. Pete-NZ

    Pete-NZ Been here awhile

    Joined:
    May 8, 2011
    Oddometer:
    798
    Thats starting to look pretty good....
    have sorted the seating out yet ?
  19. Feedback Cycle

    Feedback Cycle Been here awhile

    Joined:
    Nov 25, 2011
    Oddometer:
    101
    Location:
    Michigan
    No seat yet. When I do, I currently think that it will be simple, bench like. Not chair type with arms or back.
    But who knows.
  20. Feedback Cycle

    Feedback Cycle Been here awhile

    Joined:
    Nov 25, 2011
    Oddometer:
    101
    Location:
    Michigan
    I've taken the step to reduce the trail.
    Using http://www.buymotorcycleparts.com/kawasaki_parts.htm# I was able to upen two windows and compare part numbers on different models. The KZ1100 spectre is my match.

    My GPZ and the KZ share the same inner fork # as well as complete wheel /hub assembly (except for finishes).
    They use exactly the same brakes and disks. Even the fork internals (springs, etc) are the same.

    The only major difference is the fork lower (mine has a center axle, the KZ has a front axle)

    The KX does however use a different tripple tree and but I don't plan on swapping that out. I hope to just slide the replacement forks into place and swap components. Will it be that easy? Of course not.:huh

    I'll post an update when they arrive.
    Will it provide a noticeable difference? Anything could help.

    <a href="http://s1095.photobucket.com/albums/i466/168912/0022/?action=view&amp;current=GPz1100FrontWheel.jpg" target="_blank"><img src="http://i1095.photobucket.com/albums/i466/168912/0022/GPz1100FrontWheel.jpg" border="0" alt="Photobucket"></a>

    <a href="http://s1095.photobucket.com/albums/i466/168912/0022/?action=view&amp;current=K1100.jpg" target="_blank"><img src="http://i1095.photobucket.com/albums/i466/168912/0022/K1100.jpg" border="0" alt="Photobucket"></a>