Suzuki 2 Strokes

Does anyone have a decent pan for sale or know where I can buy a new or re-popped one?

I made a new leather custom cover and modified the sponge (sort of like a sponge) but the pan is too far gone. Hoping to buy over make but if I make it will be from aluminum with with re-inforcements.

Thanks in advance,

Reply to Richard77. My GT500 seat was totally rusted, so I modified a GT550 by transferring the lugs from the GT seat, works perfectly but takes some time to get the mounting holes correct.
You will not find a GT500 base thats anywhere usable.

RICHARD77 wrote:Does anyone have a decent pan for sale or know where I can buy a new or re-popped one?

I made a new leather custom cover and modified the sponge (sort of like a sponge) but the pan is too far gone. Hoping to buy over make but if I make it will be from aluminum with with re-inforcements.

Thanks in advance,

Repaired my rotten seat bases with fibre glass matting & resin, plus a seat cover spike kit off ebay. One was not too bad, the other was almost paper thin in places so a piece of 2'' x 1/4 plate was tacked in place lengthways on the top. Probably stronger than a new one when glassed up but a bit heavier than stock when the job is done. Both had split, because the seat is not supported in the middle. Fitted the pan on the bike to check the clearance before I glassed them up.

Hammering a new one out of sheet metal. Once done, I'm going to powdercoat it. It's too bad that there wasn't one available but there isn't and in 3 more weeks the weather will be nice enough to ride so I basically am running out of time...


Thanks for the help guys.

Started the Pan. Getting there.


Here's the tank in finish primer ready for the final 600 sand before color. Removed the logo bar and filled it in with epoxy so the new logo will be painted.

RICHARD77 wrote:Hammering a new one out of sheet metal. Once done, I'm going to powdercoat it. It's too bad that there wasn't one available but there isn't and in 3 more weeks the weather will be nice enough to ride so I basically am running out of time...


Thanks for the help guys.

Its looking good Richard, mines nearly ready for the summer as well.Good luck with it.

Getting closer.

Seat pan done! Ready for powder coating then covering in leather.


Stencil on tank ready for the painted logo and then clear coat, then 1200 sand and polish. Just in time for spring.

Your home made pan looks very decent, there may be some money it in for you to make a few pans and sell them on ebay.

Really good work on the steel pan Richard......the flat bars look good too.

Thanks guys. Not sure about making more tho. That was painfully more work than I thought. One sheet of steel. The hardest part was getting the bottom of the seat to line up with the bottom of the tank. Had to lower the seat by moving the bracket up into the seat which meant cutting into sponge area. clearly suzuki did not put that much time into making it perfect for the last year when they went to the 750 tank because to me that's a major flaw. I only bought the bike because it was cheap and a fun project.

Here is the original tank and seat. Someone did an okay rattle can job on the tank and an okay re-cover. Not only was the recover done incorrect, the seat pan was rotten and recovered in fiberglass, except they didn't sandblast all the rust away first. I'm sure it was to the best of their abilities so I give them props for that!!!



I'll post pics when it's complete. hopefully next week.

Done the tank.
I used an oil based paint for the logo to give it a wrinkle effect. I originally wanted the sanded / worn / patina'd logo look. My test samples were not favorable. So when i tried this oil method it made it look like I masked over an old logo and painted around it. SOLD!!!!

Hard to tell in a photo but in person it looks amazing.

Here is my sanded logo test that looked better in my head then on a tank.

Sorry for the crappy pic, lights are hanging and the bike is dirty but finally done!!!

Finally out and about.

Did you get that black gas cap idea from RedZone?

Nope. I have a powder coat gun and only black powder. Prolly inspired from building lowriders. Black and red go so good together. What is RedZone?