1973 GT250 cafe build

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jabcb
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Re: 1973 GT250 cafe build

Post by jabcb »

Test fit of right-side T500 rearset with trial adapter bracket made out of paper.
Not quite as clean looking as left side — gap between bracket & adapter is filled by a nut + ~ 2 washers.
Image
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garry55
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Re: 1973 GT250 cafe build

Post by garry55 »

can't you cut the threaded boss (r/h side of picture) off the frame and re-attach it where the footrest r/h bolt sits?
Garry


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jabcb
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Re: 1973 GT250 cafe build

Post by jabcb »

The left rearset attachment point is the stock mount for the muffler & passenger foot peg.
The right rearset attachment point is one of the 2 stock mounts for the driver foot peg.

We thought about the different options.
Went with a no-weld solution that allows us to reinstall the stock driver foot pegs.

But, thanks for your suggestion.


Next step is to look at how the Higgspeed exhaust will affect this solution.
Then the drawings are off to the water-jet-cutter shop.
BAS (Bike Acquisition Syndrome) - too many bikes but have room for more

Suzuki:
GT750 2x75
GT550 72 & 75
GT380 72
T500 69 project & 73 project
T350 69 & 71
Honda 85 CB650SC & 86 CB700SC
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tz375
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Re: 1973 GT250 cafe build

Post by tz375 »

Is it possible to insert a threaded insert into that frame tube to match the new peg bracket that won't interfere with going back to stock should you so choose?

I had a similar issue with the Dunstall because I needed to fit rearsets with no modifications to the stock frame. Quite a challenge.
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jabcb
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Re: 1973 GT250 cafe build

Post by jabcb »

Am not sure what you are referring to.
The 2 frame locations that I’m using are already threaded.
BAS (Bike Acquisition Syndrome) - too many bikes but have room for more

Suzuki:
GT750 2x75
GT550 72 & 75
GT380 72
T500 69 project & 73 project
T350 69 & 71
Honda 85 CB650SC & 86 CB700SC
09 Triumph Bonneville SE
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jabcb
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Re: 1973 GT250 cafe build

Post by jabcb »

Now waiting with end in sight.
Parts are at painter & powder coater.

Will make a custom wiring harness.
Any suggestions on where to get wires with the stock colors?
BAS (Bike Acquisition Syndrome) - too many bikes but have room for more

Suzuki:
GT750 2x75
GT550 72 & 75
GT380 72
T500 69 project & 73 project
T350 69 & 71
Honda 85 CB650SC & 86 CB700SC
09 Triumph Bonneville SE
titan performance
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Re: 1973 GT250 cafe build

Post by titan performance »

Could you get the water jet cutter to make a new mounting plate with a big enough hole in it to go over the front lug? One bolt would hold it in place then. Your brake cable stop on the frame looks way out of line with the puller hole on the lever?
Keeping old 2 strokes alive !
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jabcb
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Re: 1973 GT250 cafe build

Post by jabcb »

Interesting idea - hadn’t thought of that.
My final adapter drawings are at the water jet cutter shop. Now just need to order wire + some little odds & ends parts.
We’ve talked about going with a single piece design at some point down the road. Will keep your suggestion in mind.

This is my first foray into CAD software + digital machining.
Was pleasantly surprised at how easy it is.
Have two other items I’m working on: a bracket for a CL450 exhaust, and an underseat bracket to hold the battery + taillight on the GT250 cafe.
BAS (Bike Acquisition Syndrome) - too many bikes but have room for more

Suzuki:
GT750 2x75
GT550 72 & 75
GT380 72
T500 69 project & 73 project
T350 69 & 71
Honda 85 CB650SC & 86 CB700SC
09 Triumph Bonneville SE
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jabcb
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Re: 1973 GT250 cafe build

Post by jabcb »

The water-jet-cut adapters turned out nicely:
Image

Parts are back from the painter & are looking good.
Powder coater should be done this week.

This is our first build & we are on pins an needles.
BAS (Bike Acquisition Syndrome) - too many bikes but have room for more

Suzuki:
GT750 2x75
GT550 72 & 75
GT380 72
T500 69 project & 73 project
T350 69 & 71
Honda 85 CB650SC & 86 CB700SC
09 Triumph Bonneville SE
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jabcb
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Re: 1973 GT250 cafe build

Post by jabcb »

Parts back from powder coater & looking spiffy.

Found really useful instructions for spoke wheel lacing on the GS forum:
http://www.thegsresources.com/_forum/sh ... sxs+spokes

And the results with NOS spokes:
Image
BAS (Bike Acquisition Syndrome) - too many bikes but have room for more

Suzuki:
GT750 2x75
GT550 72 & 75
GT380 72
T500 69 project & 73 project
T350 69 & 71
Honda 85 CB650SC & 86 CB700SC
09 Triumph Bonneville SE
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jabcb
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Re: 1973 GT250 cafe build

Post by jabcb »

Making more headway.

Image
Image
Image
BAS (Bike Acquisition Syndrome) - too many bikes but have room for more

Suzuki:
GT750 2x75
GT550 72 & 75
GT380 72
T500 69 project & 73 project
T350 69 & 71
Honda 85 CB650SC & 86 CB700SC
09 Triumph Bonneville SE
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jabcb
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Re: 1973 GT250 cafe build

Post by jabcb »

Mounted new Avon RoadRiders.
Its the third set we’ve done with a No-Mar CH200 tire changer. It has a bit of a learning curve — we are getting faster & got these tires on without marking up the powder coating.
Image
BAS (Bike Acquisition Syndrome) - too many bikes but have room for more

Suzuki:
GT750 2x75
GT550 72 & 75
GT380 72
T500 69 project & 73 project
T350 69 & 71
Honda 85 CB650SC & 86 CB700SC
09 Triumph Bonneville SE
dgoodsy
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Re: 1973 GT250 cafe build

Post by dgoodsy »

Those wheels and tires look great!
'72 GT750
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jabcb
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Re: 1973 GT250 cafe build

Post by jabcb »

Making some good headway.
Image

Test fit of salty_monk’s adapter + a Kawasaki Concours twin-piston caliper.
Image
BAS (Bike Acquisition Syndrome) - too many bikes but have room for more

Suzuki:
GT750 2x75
GT550 72 & 75
GT380 72
T500 69 project & 73 project
T350 69 & 71
Honda 85 CB650SC & 86 CB700SC
09 Triumph Bonneville SE
User avatar
jabcb
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Posts: 4240
Joined: Mon Dec 13, 2010 4:32 pm
Country: USA
Suzuki 2-Strokes: 69 T350 thru 75 GT750
Location: southwestern Pennsylvania

Re: 1973 GT250 cafe build

Post by jabcb »

Test fitting the spiffy new Higgspeeds.
Image
BAS (Bike Acquisition Syndrome) - too many bikes but have room for more

Suzuki:
GT750 2x75
GT550 72 & 75
GT380 72
T500 69 project & 73 project
T350 69 & 71
Honda 85 CB650SC & 86 CB700SC
09 Triumph Bonneville SE
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