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little sister of GS1157
http://www.hondahornet.org.uk/messageboard/viewtopic.php?f=6&t=33002
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Author:  HOON98 [ Thu Apr 20, 2017 8:13 am ]
Post subject:  Re: little sister of GS1157

This is brilliant - I'm learning so much from this thread :clap

Plus the bike is looking excellent.

Author:  370steve [ Thu Apr 27, 2017 9:16 pm ]
Post subject:  Re: little sister of GS1157

thanks Hoon.

got bike in back of car ready to take to work tomorrow, going to tack all the bits in place, strip the engine out and take the frame round
to the welders, that way he can do the work as and when he gets the chance.

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Author:  richard pitman [ Fri Apr 28, 2017 2:53 pm ]
Post subject:  Re: little sister of GS1157

Is that a Citroen Berlingo ?

Useful vehicles, I've had three of those ..

Author:  370steve [ Fri Apr 28, 2017 5:25 pm ]
Post subject:  Re: little sister of GS1157

richard pitman wrote:
Is that a Citroen Berlingo ?

Useful vehicles, I've had three of those ..


Sure is Richard, bloody good bit of kit, very versatile :)

got bike tack welded, all the bits now in place, stands a little bit too upright on the side stand, so will either
cut it back off and re weld or cut a bit off the end!
will get all the bits off and get the frame round the corner soon as posible.

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Author:  370steve [ Wed May 03, 2017 2:28 pm ]
Post subject:  Re: little sister of GS1157

frame now with the welders for final instalment, should pick her up again
some time this evening all ready for clean up and dressing off ready for powder coat.

Author:  370steve [ Thu May 04, 2017 6:23 pm ]
Post subject:  Re: little sister of GS1157

spent most of this morning cleaning up the frame, grinding down the weld infills, and removing unwanted metal.
is now all but ready for trip to the powder coaters.

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Author:  370steve [ Wed May 10, 2017 12:02 pm ]
Post subject:  Re: little sister of GS1157

frame now sorted, holes all filled with old bolts, steering head sealed with some old plates.
just need to get it to the coaters.
will be removing all the engine cases, swing arm, wheels and plates for coating too.

Author:  370steve [ Tue May 16, 2017 10:54 am ]
Post subject:  Re: little sister of GS1157

spent this afternoon going over the motor with a wire brush attachment in my drill.
came out quite well, just a few small areas that need doing (didnt have a small pointed attachment left, will be getting one)
then it will be de grease, paint and off with casings for powder coating.

Author:  370steve [ Mon May 22, 2017 8:46 pm ]
Post subject:  Re: little sister of GS1157

did a bit of work on the swing arm, removed all the bearings and cut off the brake pipe holders,
cleaned it up a bit, now ready for powder.
not found the time to do anything else to the engine, will try to do some more this coming weekend.

Author:  370steve [ Sun Jun 04, 2017 9:28 pm ]
Post subject:  Re: little sister of GS1157

bits now all ready to send to the powder coaters.
as the weather was good i finished off cleaning up the engine, gave it a couple of coats of matt black, looks darker
in real life, pics dont do it justice.
but i think it goes well with the semi gloss cases.
starter motor, generator and sump will all be semi gloss too.
found some s/steel fitments so added them too.
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Author:  370steve [ Wed Jul 05, 2017 4:52 pm ]
Post subject:  Re: little sister of GS1157

actually got round to taking all the bits to the powder coaters today, should be done for the end of next week.
booked Avril to do her CBT next Thursday, she has already done it once, but it has lapsed as she hasn't done her test inside the two year limit. she did her theory test earlier this year, so will book her a direct access course after she does the CBT next week.
will have to pull my finger out and get on with building her bike i think!

Author:  370steve [ Fri Jul 07, 2017 3:42 pm ]
Post subject:  Re: little sister of GS1157

more bits off to taff for machining, getting the rear engine mounts and plate lightened and sculpted.

spacer made for sprocket seat, and some other small bits done.

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Author:  370steve [ Fri Jul 14, 2017 9:09 pm ]
Post subject:  Re: little sister of GS1157

stuff back from the powder coaters, looks to be a good job.

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Author:  370steve [ Sun Jul 16, 2017 4:00 pm ]
Post subject:  Re: little sister of GS1157

today was the start of the final phase, i cleaned a space in the shed, set the engine in place and then went to work.

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it was then a process of laying the engine on its side, putting the frame over it, bolting it in and standing it up again.

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then fitted the front end. that was enough for now

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Author:  370steve [ Wed Jul 26, 2017 4:16 pm ]
Post subject:  Re: little sister of GS1157

did some work on the suspension link, now have it sorted and fitted, bit of work also on the swing arm, now also sorted and temporarily fitted. will do some work on the engine tonight (carb rubbers, oil feed pipes, cases)

Author:  HOON98 [ Wed Jul 26, 2017 4:41 pm ]
Post subject:  Re: little sister of GS1157

Looking great - I like the black/grey colour combination for the engine.

Author:  370steve [ Thu Jul 27, 2017 11:27 am ]
Post subject:  Re: little sister of GS1157

Took the suspension linkage back off, then gave it a coat of silver plasticoat paint along with the dog bones.
fitted the cam feed oil lines, was going to fit the carb rubbers, but for the love of me couldnt find the twats anywhere!!!!!!
spent around an hour turning the shed inside out and upside down, but not a sign of them anywhere, so gave up and went for a cool beer.
will re commence the search again later today :Bang

Author:  370steve [ Wed Aug 02, 2017 1:41 pm ]
Post subject:  Re: little sister of GS1157

after going through everything again, I found them in the bottom of a box of bits (not in the bag i was looking for!!)

so after finding them, i fitted them so they cant go walk about again.

did a test fit of the engine cases just to find out that the B12 cover is slightly different to the B6, so the powder coated B12 one i was going to fit is now surplus, i will

need to get the B6 cover coated.

swing arm is in, suspension linkage and dog bones fitted, coat of paint added to generator and starter motor.

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Author:  370steve [ Wed Aug 02, 2017 10:05 pm ]
Post subject:  Re: little sister of GS1157

got the genny done, still working on the starter motor

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then started to play around with the fitting of the dash, sort of happy with it there, will have to adjust the mounting plate to make it look cleaner.

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Author:  370steve [ Mon Aug 14, 2017 9:59 pm ]
Post subject:  Re: little sister of GS1157

fitted the starter motor and played around with the dash lights. started having a look at the harness

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Author:  370steve [ Wed Aug 23, 2017 6:30 pm ]
Post subject:  Re: little sister of GS1157

started on the wiring, going to fit Stick coils on this build, so got some GSXR600 ones and bastardised a CBR600RR coil loom to fit.

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Author:  370steve [ Thu Aug 24, 2017 9:50 pm ]
Post subject:  Re: little sister of GS1157

stripped the rear caliper down and removed all the seals and O rings, cleaned it up and took all the corrosion out of the seal groves.
have ordered re build kit, should be here next week.

Author:  370steve [ Thu Aug 31, 2017 8:31 pm ]
Post subject:  Re: little sister of GS1157

got the re build kit through the post, set about the caliper, now all back together with Ti bolts, new seals, pins, clips and bleed nipples.



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as i have now sold the CBR forks that came off the GS1157,  i went straight to work ordering lots of bits for the build

not anything big, but lots of the bits that always need replacing and seem to add lots of cost to any build ie....... Dynojet kit, gaskets, bolts, brake lines, h/lamp brackets, indicators.

need to sell some more bits now to pay for the paint work when its done  :help ​​​​​​​

Author:  370steve [ Sun Sep 03, 2017 8:51 pm ]
Post subject:  Re: little sister of GS1157

got some of the bits i had ordered so had a play around to make sure it all goes together as it should, had to take a very small skim off the axil adjuster blocks,

also needed to clean all the powder coat out of he axil hole in the caliper hanger.

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Author:  370steve [ Tue Sep 05, 2017 8:21 pm ]
Post subject:  Re: little sister of GS1157

got these bits through the post today/yesterday. h/lamp brackets, indicators and sump kit.

just few more bits to come now


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Author:  370steve [ Wed Sep 06, 2017 9:53 pm ]
Post subject:  Re: little sister of GS1157

did a test fit of the h/lamp, h/lamp brackets and indicators, like how clean it looks

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Author:  370steve [ Sat Sep 09, 2017 8:31 pm ]
Post subject:  Re: little sister of GS1157

wasnt happy with the h/lamp brackets,  i took them off and moved them around so that they now sit hod way between the top and bottom yoke.

i think it looks better.

fitted the front & back wheels, brake calipers, battery tray and new ignition housing.

starting to look like a bike again.

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Author:  370steve [ Sun Sep 10, 2017 9:47 pm ]
Post subject:  Re: little sister of GS1157

made a start on the electrics, sorted out most of the under seat items, 

also fitted the clutch lever and adjusted the actuator.


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Author:  370steve [ Fri Sep 29, 2017 10:46 pm ]
Post subject:  Re: little sister of GS1157

got the engine/shock mounting plate back from Taff, really pleased with how it has turned out.

will get round to fitting it and getting the bike back on its wheels sometime this weekend.

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Author:  richard pitman [ Sat Sep 30, 2017 2:29 pm ]
Post subject:  Re: little sister of GS1157

Gorgeous, sheer metal porn.

Neat job on the electrics as well 8o

Author:  370steve [ Sat Sep 30, 2017 3:05 pm ]
Post subject:  Re: little sister of GS1157

cheers Richard :)

Author:  370steve [ Sat Sep 30, 2017 9:18 pm ]
Post subject:  Re: little sister of GS1157

went straight too it today after having a ride on the 1157

needed to trim down the side insert spacers by about 1mm each to get into a nice tight fit.

everything else lined up just as nit was made to, not often i have that happen.

once the plate was in i attached the engine rear mounts and fitted the shock. getting there.

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Author:  370steve [ Sun Oct 01, 2017 10:02 pm ]
Post subject:  Re: little sister of GS1157

now she is on her wheels i have made and fitted the middle engine mounting plates, re fitted the sump,

sorted the side stand and adjusted it to give a bit more lean.

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Author:  370steve [ Sun Oct 08, 2017 3:15 pm ]
Post subject:  Re: little sister of GS1157

managed to get some work done this weekend, fitted the exhaust so i could try the oil cooler for fit and spacing. seems

to fit nicely, will just need to knock up a bracket to hold it in place. 

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next real job is going to be sorting the harness and electrics, but is getting there .

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Author:  370steve [ Tue Oct 10, 2017 12:22 pm ]
Post subject:  Re: little sister of GS1157

Set about the wiring last night, is going to be one of them jobs i think.
looks like there is very limited space in the h/lamp shell for all the wires and connectors, but
we will see.
started by connecting what bits i could with OEM connectors, then sat back and looked at where i need to remove bits
and where to clean bits up.
have made a start on cleaning up the loom that attaches the Moto gadget dash to the main harness, but will need to either get a remote button switch or wire it into the "pass" switch to use as the dash mode toggle.
I have removed the foot from the side stand and around 1" of leg to get the bike away from being too upright and unstable.
will make a new foot out of some steel plate and get it welded on. might need to get the push arm moved now too.

Author:  HOON98 [ Tue Oct 10, 2017 2:22 pm ]
Post subject:  Re: little sister of GS1157

Have you considered using one of those MotoGadget M-Unit wiring boxes?

Apparently they do a great job of simplifying and slimming down the wiring/electrical system:

https://bikebrewers.com/motogadget-m-unit-wiring/

Author:  370steve [ Tue Oct 10, 2017 8:29 pm ]
Post subject:  Re: little sister of GS1157

HOON98 wrote:
MotoGadget M-Unit wiring boxes?

Apparently they do a great job of simplifying and slimming down the wiring/electrical system:



Haha they dont slim down the build cost any :rollin

Author:  HOON98 [ Wed Oct 11, 2017 12:02 am ]
Post subject:  Re: little sister of GS1157

Quote:
Haha they dont slim down the build cost any


Yeah I agree - I couldn't justify the cost either when I already have the original loom available.

The cost of aftermarket rearsets and a new can to replace the originals is eye watering enough already.

Author:  370steve [ Wed Oct 11, 2017 10:00 am ]
Post subject:  Re: little sister of GS1157

I am trying to keep the build cost down to something realistic :lol (what i didnt do with the 1157)
thats why most of this bike came from either ebay or my hornet.
it has some bling yes, but it is all second hand out of my parts bin.
it will be getting "upgrades" but they will be done as and when money/time becomes available
some time into the future when the bike is on the road.

Author:  HOON98 [ Wed Oct 11, 2017 3:20 pm ]
Post subject:  Re: little sister of GS1157

Yeah - I totally understand - I'm only doing a restoration and light customisation but even at this level I can see how a project can quickly turn into a money pit if you don't stick within a reasonable budget - it's already cost me a lot more than I initially planned for as I get new ideas along the way.

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