Gold Member

[sos]

Summer is a tough time for projects. Too much to do and not enough time

Motocross season has kept us busy and I did get slightly sidetracked with a 1971 BSA Lightening project.

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That is pretty much done and being ridden now so back to the GM3.

I got the front of the GL1100 motor back together with the rebuilt water pump, got the 77 cams and rockers switched over the 1100 motor and was getting to the point where I needed to get the case repaired before I could move forward. That finally happened today.

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The old repair from what I thought was someone putting in a starter bolt that was too long. Turns out it was just epoxy filling the hole and the hole was much bigger than I thought.

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We had to build the surface up to get the starter mounts to sit flush. Then once we got to clean aluminum there were two big cracks propagating from the hole. Fortunately this was not the first repair my buddy has done.

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.

Now that there is new aluminum where the JB weld was and there is actually a threaded hole to mount the starter, I can continue prepping the motor to put in the frame

[Whiskerfish]

Nice work!

[sos]

My buddy hooked me up showing me how to cut the bushings to adapt the GL1000 front axle to the GSXR forks.

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We found a scrap piece of steel in the bin, cut the OD to match the GSXR axle, then drilled out the center to press onto the GL1000 axle end and nut.

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This allowed me to center the wheel and see if the calipers would clear the spokes. I knew it would be close, but it can’t get closer than this.

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It does clear and once I find 320 to 330 mm rotors to fit I’ll shim the calipers to center them.

Now that it is actually a rolling chassis I could mount the motor.

[sos]

Glad to finally get the motor back in the frame.

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This is the GL1100 motor in the GL1000 frame. It has the 1977 GL1000 cams, rockers and ignition.

Here’s what the GL1100 motor looks like in the frame. Once I replaced the ignition with the GL1000 ignition the motor slipped right on.

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Now it’s easier to just started redoing parts and getting them mounted.

[sos]

Been awhile since I updated this thread. We’ve had summer-like weather here until the last couple days and that has slowed progress on GM3.

I have gotten work done on the radiator, shelter, rear brakes, etc. Mostly, I got the the wiring sorted out to integrate the GSXR handlebar switches into the GL wiring harness and electric fuel pump.

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[sos]

Seat and body panels are only on to figure out what to do with the rear fender, taillight, seat, etc. Not 100% sure which direction I’m going for a final product. Originally was thinking cafe, then a mild touring bike and now I’m not sure again.

Having the body panels on did allow me to mark the lower triple trees for the steering stops. Also, I got a steering damper with the GSXR front end so I’m looking for a way to mount that.

Now that it’s cold out I’ll have more time to spend on this bike.

[Gowing]

Beautiful legs.

[sos]

Why thank you

[sos]

I got a 1978 parts bike that had been sitting outside for at least a decade. Pretty rough. Had to unload it with a forklift because both wheels are locked up. I wouldn’t have bothered with it except it has a 4 into 1 exhaust that I’m going to try to fit to GM 3.

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Looks like the pipe is stainless steel which explains why it didn’t rot out.

Stripping anything I though I could use, and there isn’t too much, I found that the motor and carbs are actually 1977. So I’ll pull the cams and rockers. That was a nice surprise.

[sos]

Got the parts bike torn down as far as I’m going to. Carbs are good, cams not so much. Still got lots of rubber bits, electrical harness, switches, etc.

Time to send the rest down the road.

Also got a pic of the steering stabilizer mount on GM 3.

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Not sure what the 3 threaded lugs on the headstock of the frame were used for, but they made a good place to mount the stabilizer.

[sos]

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Got some progress on GM3.

Got a soda blaster set up and an old school zinc plater to help with the carb rebuild. the Randakk’s carb kits are very nice too.

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Had a little trouble with one of the float needles, but got that sorted out and the carbs are leak tight with the K&N electric fuel pump.

Electronic ignition set and a start up. Runs good. A bit of smoke on deceleration, but I think that will work itself out.

Recap: 1977 GL1000 frame and body, 1981 GL1100 motor with 1977 cams and ignition, 1976 carbs, 4 into 1 exhaust, 2002 GSX-R1000 front end and brakes.

[Fred Camper]

Wow, you are getting very close to completion. Great progress on the front end. Love it.

[sos]

TY!

Still lots to do.

Make front disc carriers for the 320mm rotors, upholster the seat, build mounts for front fender, mount headlight and speedo, etc.

Been a bunch of fun so far.

This week will be refinishing the rear wheel and lacing with new spokes.

[sos]

Preparing the rear wheel from the parts bike for new spokes.

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The bearing retainer was completely stuck. Drilled out the stakes, but no amount of penetrating oil or heat would let it budge.

Ended up welding out the aluminum retainer to save the hub.

[Fred Camper]

They can be a bugger. Slightly oversized drill is okay, but you are correct that they still want to be tight. Glad you got it out.