New life for an old GSXR part trois

Update #1:

Several new developments have taken place since the last post so I figured it was time to update this thread.

The head light bucket arrived and is exactly as described. I thought to use the head light from the 1992 head light bucket to replace the missing one on the 1989 head light bucket.

That was a definite no-go as the bulb housing is different from ‘89 to the ‘92. Looks like I have to find another bulb housing to replace the missing one now.

The upper fairing stay/head light bucket mount also arrived and is completely not the correct one. It was listed as for an 88-89 but is actually for ‘86-‘87 MYs. Not sure where I want to go from there.

I could keep searching for an ‘89 or I can get some tubing and just make my own. Apparently the ‘89 is a blend of the ‘87 & ‘92. As I have both now, should be able to just copy the parts of each to make one and weld up a reproduction.

Some months back I got a PDR kit from Amazon for around $18. Mainly I got it for the puller bridge which is alloy and I figured would work no matter what I used to attach to the dent. Here’s the tool with some of the “sticks” for dent pulling:


The tank had 3 dents, each differing in type & complexity. Starting on the right side of the tank, there was a fairly deep, but also complex dent where the metal was stretched. For that I got some similar length bolts of the same thread from the hardware store and welded them on the dent.


This worked quite well and I was able to pull the dent almost completely out. It’s out enough for a thin layer of filler to take care of what’s left.


Here you can see all the remaining low spots….the dent was that big and that deep. There was a small dent on top of the tank that came out just with the tools in the kit. If I were not painting the tank, it could just be buffed out and waxed it came out that good. Then there was the dent on the left side of tank.



You can see the depth from the space behind the tape measure. As bad as it looks, this was a pretty easy dent to pull. I only used the included tools, and glue sticks. The only tool outta my tool box was a hammer to help tease the dent out.



Below after a quick block sand to find the low spots:



Ready for filler and primer. More later when I get back to this

Update 1.5:
I was going to wait until I made more progress on this project before a full update, but consider this one about halfway to a full one. There was one other bit of damage I did not include in my previous posts.

Due to being poorly packed for shipping the Barb fitting on the top of the vent “hump” was pushed in. This created a dent that popped the paint off in the affected areas. I was at a loss for how exactly to tackle this dent due to its location and the height of the vent bump above the rest of the tank.

I was struck with a bit of inspiration and the solution was stupidly simple. I used a claw hammer and a bit of 2X6 as a fulcrum and popped the dented in hump right out. Above is the result.

Once that was done, I got out some carbon/Kevlar cloth out to get a nice thin base layer for the filler to bind to. First though, I had to ensure there were no pinholes incurred by welding on the damaged part of the tank.

I poured in a bit of paint thinner (mineral spirits) and found there was indeed a pin hole. After draining off the thinner and waiting quite a while for it to flash off, I welded a bead around the area where the leak was. Didn’t work, made it worse. Repeat the process and finally after a much more extensive bead than one would think necessary, no more leak.

Wiped down with alcohol and set to patching the repaired area with a layer of carbon/Kevlar. I use a West Systems marine grade epoxy for this sort of thing. I call it a “bullet proof” repair. Just because of the Kevlar….bullet proof vests and all that.


Once this cured for a week or so, I sanded it back a bit with some 220 grit. After another wipe down with some alcohol, I mixed up a small batch of filler. Probably less than a teaspoon worth. Once applied and cured, I used a wood rasp to take down the high spots. Once it was shaped more or less as it should be, I hand sanded with a block and some 220.



Little more to go on this spot. A skim coat for sure and maybe a bit of glazing putty to fill any tiny imperfections. Anyway, that’s it for the mini update. More later

Further updates:

Found a new to me upper fairing stay from the UK a while back. It arrived a few weeks ago but the weather has been rainy and chilly so I left it in the box and shoved it into the garage.

Before that gem arrived I’d found a suitable headlight bucket for around $40. It was clean and undamaged but missing a light.

my original thought was to use a light from the original headlight bucket but that proved impossible. The later headlights are larger in diameter than the earlier ones.

Found a second headlight bucket that was damaged but complete with both lights for another $40. So, after $80 I have a complete headlight bucket ready to install in its period correct upper fairing stay.

A new upper fairing is in the cards soon. Once I have that, and it’s all ready to mount I’ll post some pics.

Still not ordered the upper fairing but did get the head light bucket cleaned up and installed in the upper fairing stay. Dropped right in with no surprises.

Gives me hope that the result will be the same when I go to install the assembly on the upper fairing. Once I made sure the bucket would mount in the upper stay properly I cleaned it up and mounted it with some Ti flange bolts I’ve had for a bit:



The tank is coming along nicely too. Got the remaining filler shaped and sanded down. Got a few more pits to fill and then shoot more primer. Getting close though.

Couple o’pics…..shot some blue today. Suzuki dark blue pearl to be exact. Still gotta wet sand and shoot some clear but coming along, little by little.



Prolly nothing tomorrow though….wind is already over 20 mph….supposed to pick up tomorrow

venomclawz said:

i also have an old oil boiler and stash of some parts let me know if you'd potentially need anything, i love these bikes alot.

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Potentially at least, I only “need” some new ‘glass to convert from the 1992 body that I currently have and is mostly intact to a 1989 body. Not looking for original parts really. Reproduction ‘glass is fine for my purposes.

I have all the other parts to finish the project but always on the lookout for NOS stuff or better condition used stuff. The bike was totaled out by the insurance company before I ever bought it.

The body was basically destroyed along with front fairing stay, steering stabilizer, headlight and mirrors. The forks looked like bananas. Left side engine cover (starter/generator) was ground through and leaking. Shift lever was snapped off and left handle bar broken off.

All the destroyed, broken or bent parts were replaced and I put another 25K miles on it. Then I got hit by a college kid in a Volvo. Side swiped on the freeway. All the mechanical damage from that was fixed except the steering stabilizer which Inhave an OEM one to replace the Daytona that was destroyed in that accident.

I guess what I’m sayin is “whaddya got?” Or rather what are you willing to part with? My “needs” are mostly small parts. I have one new to me switch pod, the left side I think. I dunno, I still haven’t opened the box. Wouldn’t mind finding a clean one for the opposite side. Really need to inventory what I have and don’t have