The rehabilitation of Sir Gustave Sabastian (‘Gus’)

Discussion in 'New Zealand' started by Box'a'bits, Aug 22, 2010.

  1. Box'a'bits

    Box'a'bits In need of repair

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    If I go down that route (which is not yet decided), I'm likely to put a little screen on.

    The big advantage of dropping the existing fairing is weight drop, & potential improvement to crash 'survivability'. Plus I would expect to be able to flog the surplus bits off, which would help me do other things...

    Good to see your posting up in the 'Diary' BTW.
    #61
  2. NordieBoy

    NordieBoy Armature speller

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    Easy enough to do a fairing on a round headlight.
    #62
  3. Box'a'bits

    Box'a'bits In need of repair

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    Yep, I keep looking at your DR & thinking that's a really great set up. :bubba
    #63
  4. Padmei

    Padmei enamoured

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    When you get a chance could you post up a pic of your bash plate? It looks to be better than my pie tray one & will look at making one up at a later stage.
    #64
  5. guzzitony

    guzzitony Guzton

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    :lurk

    So that tank on yet Steve? It's gonna make mine look like a h-ferguson peanut tank methinks.
    Hey Padmei, pm me your email and i can send some pics of mine if you want, f..ked if i can post any on here.....
    #65
  6. Padmei

    Padmei enamoured

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    Thanks Guzitony PM sent.
    #66
  7. Box'a'bits

    Box'a'bits In need of repair

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    Okay, so removed the fairing. The trick is to go at it in a methodical manner, and don't try to remove it all in one go. Too much wiring hiding in there that you can't see to uncouple.

    The fairing panels come off in this order - screen, side panels (see photo), undo speedo & tacho (knurled nuts hold them one like accessory dash gauges). Then remove the wiring, then the two allen head bolts holding the stay to the headstock, then the bottom roo bar holders. Course that's not how I did it, but the wisdom of hindsight.

    [​IMG]

    The wiring for the ignition is connected back at the frame spine (the black plug with ears).
    [​IMG] [​IMG]

    Thank god that bugger is off. However this has exposed the rusty fork stauntions tops. Some has polished out but there is some pitting I'll need to do something with. Purely cosmetic.

    Padmei, here's Rob's version of a bashplate. The plate gives some protection to the headers. In common with most BMW B/plates, this one bolts onto the sump. I'm going to countersink the bolts, with a wider head to spread the load a bit. There's 4 spacers which the bolts go through, between the plate & the bottom of the sump. You can just see one in the 2nd photo.

    You might also want to look at the stock PD B/plate, Touratech item, & also Twin Headlight Ernie's (a vendor here). THE's version is probably the best of them.

    [​IMG][​IMG]

    Actually the most vulnerable area is the collector box. Mine is v.strong, but has been well beaten, & you can see where it has been driven onto the frame from a top down view. Need to fit a plate to the main stand, ala Touratech & others.

    [​IMG]

    Now the fairing is out of the way I can do a 'test' fit of the tank (already knowing that it won't fit). I'll need to move some electrics (the grip controller & Enduralast regulator I've just fitted) & the oil cooler. And I need to chop the seat base up a little.

    [​IMG][​IMG]

    Finally, I've also tonight ordered the Baja Designs 8" race light & H4 conversion. :rayof :wings Heres Airhead Wranglers Baja light set up. Note 'on the fly' adjustment at the top. I've ordered (separately) an H4 conversion - otherwise the race light is single beam.

    [​IMG][​IMG]

    I'll need to run an electronic speedo with this, but for an interim period this'll be a cycle computer. It will also mean in the short to medium term I can deal to the gearbox vent (re-route this to the airbox).

    So I guess that means the existing GS fairing & clocks are available for sale if anyone decides that they want them. :wink:

    I thought yours was 40l - not small by any stretch...
    #67
  8. guzzitony

    guzzitony Guzton

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    haha thats wot they all say.............:lol3

    Mossrax in behind maccas on the basin reserve can make up legal braided stuff and not too dear.
    I've got a standard seat ifyour cutting yours up if you need to borrow it at any stage. just as long as its not an adv ride i want my small tank as well then we'd have to fight for it.:pynd




    .
    #68
  9. Box'a'bits

    Box'a'bits In need of repair

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    Took the day off today & was in to see Mossrax today (as it happens), to get the brake line made up. :rayof

    Also to Dynaflow to get some longer oil cooler lines made up, so I can move the cooler away from the crashbar & into the centre of the frame. I took my RS cooler in to show them what I wanted (+9cm) & the buggers misunderstood what I wanted to do, & cut the lines up!!!. :cry But they are making good.

    Thanks for the offer of a loan of your seat. I'll likely do some temp 'adjustments' to my seat, & ride with those for a while. We should be all good (hopefully).
    #69
  10. Padmei

    Padmei enamoured

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    OK tell me what I overpaid for my brake line:D
    #70
  11. ztaj

    ztaj jatz

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    You got royally screwed, infact..... you'll probly be walking funny for the next 2 weeks :D

    Sorry.. I'll get me coat....
    #71
  12. Box'a'bits

    Box'a'bits In need of repair

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    You paid about a 25% surcharge for the 'convenience' of a made up hose. But wait, there's more! Did you get to chose the colour & the type of fittings used? :wink:
    #72
  13. Padmei

    Padmei enamoured

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    Thanks for the rundown Steve re the fairing. That headlite/tank combo will be the bizness.
    #73
  14. Box'a'bits

    Box'a'bits In need of repair

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    Fitted the newly Dynaflow oil cooler hoses to the GS Oil cooler. The old hoses were quite corroded onto the cooler, & I was concerned that I would bend or split the cooler trying to take the old hoses. off. Eventually shifted them with patience & a blow torch.

    [​IMG]

    The new hoses are slightly too long, and because Dynaflow put the RS fitting on, I needed bend them somewhat to get clearance on the exhaust. I ended up dropping the right crashbar to make access better. I'll put that back on later. With luck (or any other forms of assistance I can tap into :pope) on my side they won't leak....because a new cooler is GBP 114 + freight, and I'd rather not have to spend that at present.

    The RS bracket has been used short term to allow the cooler to fit the frame brace. The RS & GS oil coolers are different. RS coolers hang from the top of the cooler. GS's are bottom mounted. When I was using the RS to test fit this I wasn't aware of this.

    [​IMG]

    I will need to space out the front mudguard to clear the cooler. The medium term fix is a different guard (maybe Acerbis Baja- or something full of holes), because I will need to get better air flow back to the cooler to make it effective.

    I have also fitted the new brake line to the new caliper, but await the adapter to complete this conversion. The caliper has been challenging to bleed. I haven't seen the pistons on the bleed nipple side move much yet, and I'm starting to wonder if I should have rebuilt them prior to putting them on the bike. Need to change the pads at least. Suspect they are a little oil contaminated. The other caliper ws much worse. I suspect that they are from different bikes.

    [​IMG][​IMG]

    Have the tank basically fitted. Still need to move the regulator to allow this to be centred. Here's a photo which shows the conflict between the seat & tank. I'll have a trim the seat somewhat to fit.

    [​IMG]
    #74
  15. pontypool

    pontypool Adventurer

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    The driveshaft was $450, plus a thousand to get the gearbox overhauled. Cheers, Barrie W


    #75
  16. Padmei

    Padmei enamoured

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    anddddd?:ear
    #76
  17. Mark_S

    Mark_S Fair Weather Faggot

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    +1

    get working you slack bum

    get your pipe and slippers ready for a 'rapa loop sometime soon
    #77
  18. Box'a'bits

    Box'a'bits In need of repair

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    Mark, I thought you were going up to the 'Naki to talk to Triboy & Phreaky Phil about the TAT?

    Still waiting on the light & conversion holder from the US. They left the US a week ago (LA & NYC) & seem to have gone missing. I have got the Hella semi sealed H4 insert ready to go in the light. Hella 1058HD.

    Got an e-mail Friday night to say the shock has arrived at CKTechnical, so expect that Tuesday.

    Here's the link across to the Nissin front brake conversion thread.

    Mounted a Tokico 4 pot brake off an RGV250. Got the brakes working properly yesterday. The caliper pistons were sticking, which meant the pads were dragging (a lot) on the disc when the brake was released. Pulled the caliper apart, cleaned it, & reassembled. Used a small air compressor to almost pop out one piston at a time (clamped the other three, so that only one I wanted to work on could move), then split the caliper & cleaned up each pot indvidually. Used the right caliper as parts supply for a dust seal, & one piston (I was too rough removing the first piston). Dust seals were / are a little twisted, and I might look for a rebuild kit at some stage, but they are working okay now. BTW don't let the air push the pistons all of the way out. They go off with a bang, and richocet around in the caliper. Thats why one dust seal needed replacement.

    Dropped some new pads in as well. These are Premier pads PH53 (HH) Sintered. Equivalent to EBC FA158HH

    [​IMG]

    Originally had the brake line following the original route inside the fork legs. Took the opportunity to route them outside the leg when I thought about what line flex could do.....(eh GuzziTony) :lol3

    Note that the Advrider site thread re brake conversion is wrong re the 4 pot Tokico caliper I have. It indicates caliper piston sizes at 30mm & 27 mm, ie smaller than the Nissin, which is 34mm & 30 mm. That would mean that these don't work with the 13 mm GS mastercylinder. However in fact they are 34mm & 30mm, just the same as the Nissins.:wave Had me worried for a bit there when I re-read that thread. I'll drop a correction on that thread.
    #78
  19. Mark_S

    Mark_S Fair Weather Faggot

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    it all got a bit hard and the weather wasn't looking too flash so, as usual, I bailed :cry
    #79
  20. igormortis

    igormortis Cafe Reise

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    Now this thread proves that I don't check the NZ forum on here often enough. Late to the party, but great stuff!
    #80