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GS500 build thread... cf tanks, internal supercharger, etc

my dads an engineer and he approves of this thread.
 
Awesome project. I can't wait to see how it turns out.

Question: If this is for a Sr project, shouldn't you have dyno'd the engine to get a baseline before building it?
 
wilit said:
Awesome project. I can't wait to see how it turns out.

Question: If this is for a Sr project, shouldn't you have dyno'd the engine to get a baseline before building it?
Click to expand...

Planning on taking in a stock engined GS when I do the final dyno session for comparing.

Ideally, I would have, yes. However, the bike had a handful of mods on it when I got it, wasn't properly jetted, and ran pretty crappy accordingly, so any baseline measurements would have been pretty useless.
 
Reworking the rearset design.
rearsetv2.jpg


This way parts are interchangeable between the left and right side. Should someone crash, this makes part replacement way cheaper/easier.
 
Are you mounting the master cylinder to a different part of things than the pegs? Because if you are, when you move the pegs, you might not be able to properly actuate the master cylinder.

(I figure you've probably thought of this but never hurts to make sure...)
 
With both sides. Still haven't done the heel guards yet.

rearsetv2render.jpg



Heel guards... cnc machined aluminum or carbon fiber plates? any opinions?
 
Z3n said:
Are you mounting the master cylinder to a different part of things than the pegs? Because if you are, when you move the pegs, you might not be able to properly actuate the master cylinder.

(I figure you've probably thought of this but never hurts to make sure...)
Click to expand...

rearsetmastercylinder.jpg


Separate piece that moves with the pegs.
 
Interesting design. :thumbup

Personally, I'd consider if it's possible to somehow integrate it into the peg. Because it seems like it be a pain to thread a bolt through all 3 parts simultaneously, when you're dealing with the limited space behind the rearset.

Also, which parts would be threaded?
 
Question about the CF tank:

Long thread so if I missed it, my apologies.

Are you planning on using a bladder inside the tank? If not, what epoxy or resin did you use? You need to be careful, as not all resins and epoxies are resistant to gasoline. Should be a spec sheet with the epoxy you use, to let you know. I usually use Isophthalic, personally, for applications where the part is exposed to fuel or oil and/or heat.

I make Carbon fiber and Kevlar suppressors and other FA parts for a FFL. :)

Great frikin job, btw!
 
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mllcb42 said:
With both sides. Still haven't done the heel guards yet.

...

Heel guards... cnc machined aluminum or carbon fiber plates? any opinions?
Click to expand...

Do the plates in Alum and the pegs in biaxial CF. THAT would be pretty unique. It's a pretty simple process doing the pegs (a cylinder) with biaxial CF.
 
Z3n said:
Interesting design. :thumbup

Personally, I'd consider if it's possible to somehow integrate it into the peg. Because it seems like it be a pain to thread a bolt through all 3 parts simultaneously, when you're dealing with the limited space behind the rearset.

Also, which parts would be threaded?
Click to expand...

Planning on just threading the mount for the brake master cylinder.

The reason I didn't integrate it into the peg, etc is that this way I can use the same parts for both sides. If I make a piece with the brake mounts integrated, I need to have a different piece for the other side.
 
wrexallen said:
Do the plates in Alum and the pegs in biaxial CF. THAT would be pretty unique. It's a pretty simple process doing the pegs (a cylinder) with biaxial CF.
Click to expand...

I have the biaxial carbon here for doing cylinders. I'm more concerned about the safety of doing a carbon peg. Crash and it won't bend, it'll shatter, leaving some sharp pieces attached to the bike next to your leg. I could use kevlar like I did in the tank, but why? Some shiny carbon pegs would likely end up all scratched to hell with minimal use, so you lose the aesthetic reasoning in a hurry.
 
wrexallen said:
Question about the CF tank:

Long thread so if I missed it, my apologies.

Are you planning on using a bladder inside the tank? If not, what epoxy or resin did you use? You need to be careful, as not all resins and epoxies are resistant to gasoline. Should be a spec sheet with the epoxy you use, to let you know. I usually use Isophthalic, personally, for applications where the part is exposed to fuel or oil and/or heat.

I make Carbon fiber and Kevlar suppressors and other FA parts for a FFL. :)

Great frikin job, btw!
Click to expand...

The epoxy I'm using is listed as being nonreactive with gasoline. I will also be coating the tank fuel a gas tank sealant just for added piece of mind.
 
lot of work on such an old bike will it ride like a new one or somewhere inbetween cuz old bikes vs new bikes no match
 
h2v7 said:
lot of work on such an old bike will it ride like a new one or somewhere inbetween cuz old bikes vs new bikes no match
Click to expand...

GSXR front suspension, R6 rear suspension, modern brakes, and a supercharged single that makes full boost at 0 rpm?

I can't imagine it'll ride much like anything out there, new or old.
 
Mllcb42: Any thoughts as to how well the tank will survive a crash? I would be interested for race use, but I need to confirm that it would withstand some pretty severe abuse, and wouldn't pose a fire or surface hazard in the event of a major get-off.
 
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