My 77 GL full custom build

[4wheelfurry]

So I bought this 77 back in 2013 as a runner with the intention to do a full build. It sat a while but around Nov of last year I got on it and getting close to finishing it up. I have many build pics of the process so I will post them in this thread. First pics are beginning and ending

[4wheelfurry]

Right away I knew I wanted to mono shock it and do an USD upgrade. Also I wanted to hide as best as I could the cooling system. So I started cutting chopping and welding!

[4wheelfurry]

The forks are from a ZX10R Kawie, I machined off the stock stem from the triple and machined the ZX10 to press fit it into that triple so I used the factory bearings in the stem. It worked out great. As for the rear I used a shock from a Suzuk Katana because it was the correct measurement. All pipe work was fabbed up and welded by me.

[4wheelfurry]

Once I had the basic design that I liked I started on the tail section. The radiator I used is from a Suz TL1000. Dual 7" fans fit it perfectly and are switched by the Suz temp switch mounted in the radiator. So using the rad I fabbed up how I wanted the rear to sit with tubing and just made it all fit!

[4wheelfurry]

So the seat was a flebay special, the measurements were what I needed so using the seat I made a tail from steel and glass. I do have some leather I plan to recover the seat and change the pleating and thread design. So this isn't the final look on the seat but it is for the tail piece.

[4wheelfurry]

Once that was done I finished up the swing arm bridging and put everything in some good 2 part urethane primer.

[4wheelfurry]

So I went rounds and rounds on color choice. I am not a fan of white, in fact it's my least fav color.. And pretty much everything I build is black or some combination with black. But for this build I went against my feeling and chose blue frame and pearl white bodywork. Then as for drivetrain I knew I wanted wrinkle finish flat black. So I media blasted everything and sprayed it. Turned out really nice!

[4wheelfurry]

I blasted the wheels and sprayed them. Black spokes and blue rings with a white stripe, new shoes. The front fender is a glass fender I built a few years back for another bike project, it got removed and so I reused it on this build.

[4wheelfurry]

Once the bodywork was sprayed and dry I mocked it up, by this point I still had a long way to go but I was getting excited!!

[4wheelfurry]

A few things I will cover, the rear brake master is a ebay special I fabbed up mounts for. The front calipers fit the factory rotors I just had to trim the mount pedestals. The controls are original Goldwing, I blasted and resprayed them. The bars are some low sport bars I got off the net. I just drilled the upper triple and threw some risers on it. I rebuilt the rear caliper and the front master. Custom length lines finished off the brakes.

[ritalz]

That's quite a transformation. Very sporty. Nice job.

[4wheelfurry]

Once all this was done I started on my dash, controls and wiring. The headlight bucket is from a HD, I built a bracket that bolts to the head so nothing moves with the steering. I have 3 gauges, a GPS speedo, a temp gauge and a small tach that will run off the coil. The dash fabbed up from sheet metal and 3/16 rod. The wind screen is a internet special, I trimmed it to look better and painted it to match the bodywork.

[4wheelfurry]

So with the carbs I went with 40IDFs cable operated by a 69 CB350 splitter cable. I made the manifolds and brackets. The air filters are individual paper puck filters that slide down inside the horns off of an air pump.

[4wheelfurry]

The battery is a small Lith Ion with 330CCA. Dyna CDI conversion and coils. The regulator is for a Lith batt. I built a battery box and then attached everything to it and it is all hidden under the tank. All wiring done by me, I ran the circuits I wanted and left out the rest!

[4wheelfurry]

On the exhaust I wanted something small and hidden to really show off the frame. So I built a collector muffler using the stock head pipes and thermo wrapped them. One of my last issues was running the coolant lines. The supply runs under the bike, I fabbed up several steel pipe bends and such. The return (off the heads) runs through a T and into a steel line back to the rad.