Lowering the GL1000 - Page 5 - Steve Saunders Goldwing Forums

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post #41 of 187 (permalink) Old 11-28-2011, 09:17 AM Thread Starter
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Sunday 11/27/2011

I took it a little slow today, time for thought and design ideas.

After chopping of the shelter supports and cleaning off the tabs I sat down to figure out just how to mount the gas tank.

The center support tube was rather large at the neck and tapered down to a smaller size.

In order to get a good solid support tube to put down the center I decided to cut the top and sides off this center tube.



When I did this I found that the original center tube was not welded to the neck but to an outer shell which is welded at the top and bottom to the inside neck.



My idea now is to weld the new tube along this bottom tube housing and then gusset in the top pretty much like the original. I will probably wind up putting more support metal in place of the original metal because I want the neck to look smoother and more finished than the original.

I have to make sure that the height of the tank leaves enough room for the air filter.

Now on the subject of air filters, I have gone overboard and purchased a single carburetor manifold to mount on the engine going into this bike.

It uses a single VW Solex 34 PICT Carburetor, which I am familiar with already, having build a few dune buggies in the past.

This I hope this will make tuning easier + I will only need one pull cable to operate the carburetor. Time will tell.

I hope this also gives me more room above and around the engine.

Now I have to figure out just how to mount the other end of the center bar.



1967-69 Vietnam Vet
Life Member DAV
Patriot Guard Rider

1996 GL1500 SE Trike
1980 GL1100 Naked and Low
(1) 1975 GL1000 (being lowered)
(5) 1975 - 79 GL1000 Parts bikes

"Never try to teach a pig to sing
It wastes your time and it annoys the pig."

"You can also follow me on my blog Zimco\'s Garage"


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post #42 of 187 (permalink) Old 11-29-2011, 06:21 PM Thread Starter
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I took yesterday off, Cyber Monday and I had to Christmas shop for the wife.

After all, she's the one I can count on to hold the bars steady when I tack them and bring a fresh coffee when I am in the garage meditating on my next move. Almost anything I need that I can't do myself.

Today is Tuesday 11/29/2011



I decided to go with a Kawasaki tank I had in the Garage loft, it has some nice lines that seem to go with the frame design.



Here are a couple of views of it mocked up on the bike.



I had to put the triple tree back on (dumb) to check for gas tank clearance in the front.



I ground a slot and welded a 4 inch rod in it to accept some Honda gas tank rubbers which happen to be the same size as the Kawasaki tank mounts.



I then cut and ground a plate to replace the original front gas tank mount and tacked it in.



I tacked a flat piece of scrap to the end of the tank tube so that when the plate is level I know the tank mount rod is also level. The end of the tank tube will be cut off at an angle to mount on the flat plate.

I also welded a smaller piece of tubing that fits into the front of the tank tube and also fits into the front mounting area better.

I have been centering the tank between the fork neck and the center of the rear tire.

At this point I think I am happy with the set-up so far.

1967-69 Vietnam Vet
Life Member DAV
Patriot Guard Rider

1996 GL1500 SE Trike
1980 GL1100 Naked and Low
(1) 1975 GL1000 (being lowered)
(5) 1975 - 79 GL1000 Parts bikes

"Never try to teach a pig to sing
It wastes your time and it annoys the pig."

"You can also follow me on my blog Zimco\'s Garage"


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post #43 of 187 (permalink) Old 12-01-2011, 08:40 AM Thread Starter
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Wednesday 11/30/2011

Spent most of the day forming the rear mount for the gas tank tube.

This amounted to cutting two pieces of plate tacking them to the tank tube.

There are a lot of variables that go into clamping the tube pieces together.

The whole tube must be straight and centered, the pegs for the gas tank must be level, then the side plates must be at a 90 degree angle with the frame plate.

After about a half hour of trying to get them right and failing, I got my helper out to the garage (wife Betty) we were then able to hold all the parts on the right angles and clamp them. I then tacked the pieces to the tube only.



When I was sure everything was right I welded the top of both pieces.



I cut off the tube end on an angle and made a support plate for the front and rear of the rear section.



I cut two small pieces of plate to cover the front and rear of the pieces I tacked on. I welded the rear piece only about half way down then heated it and bent it to match the rear angles.



The bottom portion of this plate will be cut off flush and the whole rear section will be filled and ground smooth, then the unit will be ready to weld to the frame front and back. I will then weld, fill and gusset the front of the tube where it attaches to the neck.

1967-69 Vietnam Vet
Life Member DAV
Patriot Guard Rider

1996 GL1500 SE Trike
1980 GL1100 Naked and Low
(1) 1975 GL1000 (being lowered)
(5) 1975 - 79 GL1000 Parts bikes

"Never try to teach a pig to sing
It wastes your time and it annoys the pig."

"You can also follow me on my blog Zimco\'s Garage"


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post #44 of 187 (permalink) Old 12-02-2011, 09:09 AM Thread Starter
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Thursday 12/01/2011

I filled and ground the rear portion of the gas tank mounting tube.



"fill and grind, fill and grind"



After calling my helper (Betty) out to the garage, we got it set-up and tacked to the frame. A little light hammering brought the original "sheet metal" from the bottom leg of the frame over to match the new gas tank tube.



There is going to have to be a lot of filling done to match the top of the tube to the neck.
I will use 1/8 inch filler between the neck and tube not sheet metal like Honda uses.



I set the gas tank on and marked the rear mounting hole, drilled and tapped it to take a 8mm X 1.25 bolt. I also cut a rubber bushing I had in half to go under the gas tank mounting tab.

At this point I did notice that the clearance between the front neck and gas tank is very small, about 1/8 inch but it does clear and won't hit on tight turns.



I got out a trailer fender I had in the garage left over from a Honda 400A build.
I had to buy two at the time.)





I think there won't be too much clearance between the tire and the fender but I like the look.

The rear fender is rushing it but I had to see how it would look.
I still have to fill the neck area and gusset it in, then weld the rear of the tank tube mount in.



1967-69 Vietnam Vet
Life Member DAV
Patriot Guard Rider

1996 GL1500 SE Trike
1980 GL1100 Naked and Low
(1) 1975 GL1000 (being lowered)
(5) 1975 - 79 GL1000 Parts bikes

"Never try to teach a pig to sing
It wastes your time and it annoys the pig."

"You can also follow me on my blog Zimco\'s Garage"


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post #45 of 187 (permalink) Old 12-02-2011, 09:15 AM
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This is looking great!
There a lot of work in this project that a welder would like.


USMC, Vietnam Combat Vet. 69-70,
GWRRA 78111
PGR 255645
1st Bike Honda Dream 150 Dream Bought in \'68
1st GoldWing GL1100 Interstate
1989 GL1500/6 (NEW)Still have runs GREAT
Now:1993 Gl1500SE Future Trike

To many projects to finish
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post #46 of 187 (permalink) Old 12-03-2011, 09:44 AM Thread Starter
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Friday 12/02/2011

First step today was to fill in the area at the top of the neck with some short pieces of 1/4 inch flat stock. then clean and
smooth the welds on the neck so everything is flat to accept the plates.



I cut two plates out of 1/8th inch plate I had laying around, smoothed them and cleaned up the surface rust.



Honda uses a much thinner metal between their frame tubes, but I like a minimum of 1/8th inch just for strength.



The process is very labor intensive but it works for me in the end.



I tacked in the right side with a little bit of hammer forming then welded it solid.



This is the left side before plating it.



Left side plated and also ground for the first time.

I will grind all the welds smooth and fill the gaps again by doing more welding and grinding.
This way there will be a minimum amount of fiberglass in the finished frame.
I fill the low areas then grind so that I don't loose the strength of the original weld, it takes a while but I think it is worth it.

Even though most of the front is hidden by the gas tank I will fill and smooth it anyway. I even wound up touching up Honda's welding
on the front bottom tube or should I say lack of welding because there were open areas where they didn't weld it at all.

I will also weld and grind down the two dots where Honda spot welded an insert into the bottom tubes (see above photo).




1967-69 Vietnam Vet
Life Member DAV
Patriot Guard Rider

1996 GL1500 SE Trike
1980 GL1100 Naked and Low
(1) 1975 GL1000 (being lowered)
(5) 1975 - 79 GL1000 Parts bikes

"Never try to teach a pig to sing
It wastes your time and it annoys the pig."

"You can also follow me on my blog Zimco\'s Garage"


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post #47 of 187 (permalink) Old 12-04-2011, 11:02 AM Thread Starter
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Saturday 12/03/2011

Spent most of the day welding and grinding on the neck.

Nothing in pictures because I still have a lot to do,
I hope to finish the neck and tank mount today.

"Hang in there"

1967-69 Vietnam Vet
Life Member DAV
Patriot Guard Rider

1996 GL1500 SE Trike
1980 GL1100 Naked and Low
(1) 1975 GL1000 (being lowered)
(5) 1975 - 79 GL1000 Parts bikes

"Never try to teach a pig to sing
It wastes your time and it annoys the pig."

"You can also follow me on my blog Zimco\'s Garage"


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post #48 of 187 (permalink) Old 12-05-2011, 09:12 AM Thread Starter
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Sunday 12/04/2011

I finished most of the filling on the neck area and ground it smooth.
Before the frame is ready for primer I will glass up all the small imperfections.

I have decided I don't like the look of the rear tank tube mount.
I haven't come up with a fix yet but I am thinking of adding a piece
of stock on an angle from the center to the out side frame to smooth it out.



more thought on that later.



I added a rear fender mount to the swing arm, then cut a slot in a block of wood
and tied it to the wheel with a pull tie so I could move the wheel around until
I got the rest of the fender to sit where I wanted it.



Now there is a choice that I am having a hard time with.



Does the fender get cut off at the pull tie (like I first thought) or some where
between where the tie is and the end?



After sitting and looking I also like the look of the longer fender.

What do you think? If the tie is in the 12 o'clock position and the end of the fender is 9 o'clock, where do you think it should be cut?

I am taking Monday off to rest up a bit, so let me know what you think.

I would also like input on the rear Tank tube mount.



Thanks

1967-69 Vietnam Vet
Life Member DAV
Patriot Guard Rider

1996 GL1500 SE Trike
1980 GL1100 Naked and Low
(1) 1975 GL1000 (being lowered)
(5) 1975 - 79 GL1000 Parts bikes

"Never try to teach a pig to sing
It wastes your time and it annoys the pig."

"You can also follow me on my blog Zimco\'s Garage"


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post #49 of 187 (permalink) Old 12-05-2011, 09:34 AM
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How bout maybe a "V" cut at 7:30 on rear fender?
Maybe adding sheet metal to the sides of the tank down to the frame.
Do it in card board & tape it first for a look see.
Or maybe move the top tube in if you can.
Looks a little boxy now.
Then you could wrap the seat around the tank to cover the mount.
Just some ideas, your work is great.
Wish I would get more ideas on my posts.
Some good, some go in the trash, but they all get my mine working.



The neck looks great & very good workman, it shows the detail you do.



USMC, Vietnam Combat Vet. 69-70,
GWRRA 78111
PGR 255645
1st Bike Honda Dream 150 Dream Bought in \'68
1st GoldWing GL1100 Interstate
1989 GL1500/6 (NEW)Still have runs GREAT
Now:1993 Gl1500SE Future Trike

To many projects to finish
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post #50 of 187 (permalink) Old 12-07-2011, 01:37 PM Thread Starter
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Wednesday 12/07/2011

Pearl Harbor day wow 70 years ago.

Haven't posted the last few days, mainly because I haven't been in the garage.

My Neuropathy is acting up again, and my hands don't work the way they should.

I also have a friend coming over today, he broke a key off in a ignition lock and I need
to get it out for him then make a new one from code if the lock has a code on it,
otherwise I will try to make one from the broken piece.

Years ago I did locksmithing and I kept all my machines, I also added
motorcycle key blanks to my inventory and I keep up on the codes to make them.

Note always keep at least 2 keys minimum for each lock you own,
it will save you dollar$ in the long run.

Also doing a lot of thinking about the bike design.

I only received one reply to my questions for building the bike, but what a great reply.

Skip has some good ideas, I am trying to figure out if I can do them.
I have a limited amount of tools here in my shop, I am thinking about bending the bars for under the tank with my cheap pipe bender.

I think I will try to bend one and then duplicate it if I can.
I would then weld it on before cutting the frame.
I have a very crude bender so making the bends right may be a problem.

Skip, I don't understand your cutting the fender at 7:30 comment the choice is between 12:00 o'clock and 9:00 o'clock, there is no fender at 7:30 position.
I also maybe a little thick and that was a joke.

I still am looking for input as far as cutting the fender or fixing the tank area.





1967-69 Vietnam Vet
Life Member DAV
Patriot Guard Rider

1996 GL1500 SE Trike
1980 GL1100 Naked and Low
(1) 1975 GL1000 (being lowered)
(5) 1975 - 79 GL1000 Parts bikes

"Never try to teach a pig to sing
It wastes your time and it annoys the pig."

"You can also follow me on my blog Zimco\'s Garage"


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