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PostPosted: Wed May 08, 2019 2:37 pm 
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Joined: Wed Jul 10, 2013 12:04 pm
Posts: 981
Country: England, UK
Bikes owned: FZ50, GP100, RG125 Gamma, GT380, Bandit 1200S
Grey_Ghost wrote:
It's still moving along, just not as quick as I would prefer!

It never does! Don't worry, progress is progress. And it looks like you are doing a great job rather than a rush bodge job :up: I am watching this thread with great interest. It helps give me a little more impetus towards finishing my old smoker. So thanks for that and good luck with the rest of the build


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PostPosted: Thu May 23, 2019 7:47 am 
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Joined: Mon Apr 10, 2017 1:12 pm
Posts: 33
Country: US
Bikes owned: T500
Howdy!

Continuing the work on the Titan and am finally able to really visualize what this bike will look like when it is done! We are definitely excited for the final product. We're getting to the point where each task brings with it a greater sense of completion!

The last couple weeks has been focused on getting the seat pan built with some minor things here and there. The seat has been a big learning experience since I have never done fiberglass work before. The original seat was garbage and the underlying pan was swiss cheese from rust, except at the mounting locations and along the pan's spine. We trimmed down the rusty parts of the pan so it would provide the backbone to the new seat while still maintaining the factory mounting points. We bought some pink board foam insulation and roughed out the shape and integrated the modified pan frame inside the foam shape. We then draped the entire bike in plastic, fit the foam buck/metal pan onto the factory mounting locations and proceeded to lay the fiberglass mat. (NOTE - Pink foam board does NOT like fiberglass resin! I realized this as I watched in horror as the foam board melted away under the wet fiberglass mat! Thankfully, the mat set before too much of the foam melted away.) I have continued to lay up additional layers of fiberglass on the rear tail section as well as underneath to box in the pan and build rigidity. Next step is body filler and sanding.

I purchased a set of small, sleek LED turn signals that mount at the factory locations which really look nice. The rear tail light is fitted inside the new tail section. When the seat pan is complete I will trim down the original license plate mount and hang off the end of the trimmed down rear fender.

We have wrestled much trying to determine an acceptable color scheme. We want it to be unique, but age well. Currently, we're thinking black with red accent/graphic.

I know, this is a Suzuki forum and I run the risk of being exiled and labeled a heretic, but I figured there has to be few of you guys who, albeit secretly, would totally understand! I picked up a '75 Kawasaki H1 last weekend for a measly $400!! Motor is locked, but is essentially complete. I initially convinced the wife it would make a good flip project, but the more I think about it, I think this may become a permanent family member. I'm not a big fan of these bikes in stock form, so I am thinking about giving it the same treatment as my son's Titan. What do you guys think? I would love to hear from you.


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File comment: New LED turn signals.
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File comment: New taillight will flush mount to fit inside the new tail section. I shaped the tail to match the contour of the new LED light.
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File comment: You can see how the metal pan was cut down to fit inside the foam buck.
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File comment: Laying the mat.
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File comment: '75 Kawasaki H1 Mach III triple. Rough, but complete. I mean, $400! Admit it...You would do it too!!
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PostPosted: Thu May 23, 2019 9:34 am 
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Joined: Mon Apr 10, 2017 1:12 pm
Posts: 33
Country: US
Bikes owned: T500
sportston wrote:
Grey_Ghost wrote:
It's still moving along, just not as quick as I would prefer!

It never does! Don't worry, progress is progress. And it looks like you are doing a great job rather than a rush bodge job :up: I am watching this thread with great interest. It helps give me a little more impetus towards finishing my old smoker. So thanks for that and good luck with the rest of the build


Thanks for the compliment! I hope everyone enjoys this thread as much as we are enjoying this build! Like you, I also get a lot of inspiration and drive from the folks here who, through a lot of trial and error, create beautiful machines while working late nights in cold garages with inadequate tools.

Here's a couple pictures of the airbox assembly in its final condition.


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PostPosted: Fri May 24, 2019 11:45 am 
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Joined: Wed Jul 10, 2013 12:04 pm
Posts: 981
Country: England, UK
Bikes owned: FZ50, GP100, RG125 Gamma, GT380, Bandit 1200S
Its looking great. I like the looks of the Kwacker too. Another interesting project to play with. Hope you keep us posted on that resto also. Its the wrong forum for Kwackersakis I know, but their 2-strokes are great too!


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PostPosted: Tue Jun 18, 2019 6:52 am 
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Joined: Mon Apr 10, 2017 1:12 pm
Posts: 33
Country: US
Bikes owned: T500
Howdy!

We've (in truth, me) been working on fitting up the rearsets on the bike this last week or so. A small grinder and portable MIG welder are indispensable if you want to do any type of customization or fabrication! I bought the rearsets off eBay from a guy that had them mounted on a T500 that he raced. When I bought them I assumed it would be a simple bolt/weld on and I would be good to go. However, that was not the case. The mounting of the pegs was the easy part...the challenge was getting the linkage and shifter sorted out. The Higgspeed pipes sat too close to the shifter and I had to do some cutting, grinding, and fitting of the shifter rod. It is nestled snuggly between the pipes and the lower frame tube. It's tight, but it works.

The right side chose not to be left out of the fun, either. The linkage, when mounted to the factory tabs, stood off the frame too far and caused issues with the mounting of the rear brake cable. I removed the factory cable mount on the frame and will raise it approximately one inch so the cable enters the mount above the linkage. This will also have to stand off the frame a bit so the cable lines up properly and doesn't cause any binding. This is not completed yet, but should be in the next week or so.

Also completed was the priming and painting of the fenders. I also got the front fender mounted in its final position.

Goodies received in the mail this week included new brake and clutch levers, gas cap and bung (installation of this should be interesting!), and front brake cable.


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PostPosted: Wed Jun 19, 2019 11:18 am 
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Joined: Wed Jul 10, 2013 12:04 pm
Posts: 981
Country: England, UK
Bikes owned: FZ50, GP100, RG125 Gamma, GT380, Bandit 1200S
That looks like quite a hassle to fit. You're getting there though. Having kinda similar problems making my rear brake work when the drum brake on my GT380 (from a GS400) doesn't have a cable sleeve fitting on it. Tricky but not impossible. Keep up the good work. Thanks for showing us your progress. I reckon those rearsets make it look a lot sexier than the standard pegs.


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PostPosted: Wed Jun 19, 2019 2:56 pm 
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Joined: Mon Apr 10, 2017 1:12 pm
Posts: 33
Country: US
Bikes owned: T500
sportston wrote:
That looks like quite a hassle to fit. You're getting there though. Having kinda similar problems making my rear brake work when the drum brake on my GT380 (from a GS400) doesn't have a cable sleeve fitting on it. Tricky but not impossible. Keep up the good work. Thanks for showing us your progress. I reckon those rearsets make it look a lot sexier than the standard pegs.


It will DEFINITELY look sexier!!

Just finished up the right side last night. Little more involved than the left side. I cut off the cable sleeve, built a new tab, and relocated it north about 1.5" from its original location. Not the prettiest, but it works!


Attachments:
File comment: Cable sleeve in the factory location.
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File comment: Cable sleeve removed and located in approximate new position.
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File comment: Finished product.
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PostPosted: Wed Jun 19, 2019 5:11 pm 
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Joined: Tue Dec 16, 2008 11:37 am
Posts: 966
Location: Trowbridge UK
Country: UK
Bikes owned: T500R, SV1000S, TS125, Seeley T500
Hi Grey_Ghost

I used the same rear sets on a race build, good value for money. We cheated on the rear brake set-up by modifying a std. item.

Image

Cheers Geoff


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PostPosted: Thu Jul 11, 2019 7:13 am 
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Joined: Mon Apr 10, 2017 1:12 pm
Posts: 33
Country: US
Bikes owned: T500
Zunspec4 wrote:
Hi Grey_Ghost

I used the same rear sets on a race build, good value for money. We cheated on the rear brake set-up by modifying a std. item.

Image

Cheers Geoff


I'm cautiously optimistic about them at this point, Geoff. They look good, but feel a tad sloppy in their action and I have a little concern how they will perform off the workbench...I guess I will find out soon enough!

Began working on the gas tank this week. The original cap was in rough shape and was missing the entire lock assembly and I had not been successful in locating a replacement part. We spent some time looking for a replacement cap, as well. Finding a functional and presentable T500 gas cap over here is a challenge. They are either thrashed or cost $250! The best option we found was a tab-style chrome cap and bung purchased through Low Brow Customs. This worked out much better than I could imagined! After carefully cutting the exterior lip of the existing gas filler neck, we removed the filler neck from the tank. The Low Brow bung slipped right into the hole with a perfect fit! I brazed around the filler neck and with a little touch up with a grinder wheel, the new cap fits like factory. Very happy with the results! And the cap and bung only cost me about $20! If any of you are looking for a low budget fix on your Titan gas cap, the Low Brow setup fits like a glove!

Link for the gas cap...https://www.lowbrowcustoms.com/cycle-st ... hrome.html" onclick="window.open(this.href);return false;
Link for the bung...https://www.lowbrowcustoms.com/filler-n ... gIFqfD_BwE" onclick="window.open(this.href);return false;

I hope everyone is enjoying their summer!


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PostPosted: Thu Jul 11, 2019 1:17 pm 
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Joined: Wed Jul 10, 2013 12:04 pm
Posts: 981
Country: England, UK
Bikes owned: FZ50, GP100, RG125 Gamma, GT380, Bandit 1200S
Nice job! I like the economy and great look of this mod. :up: And I spent a fortune on a re-chromed one. :| :oops:


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