More on GS strengthening

**Mr. Ron** · #1 2 Jul 2004

Hello.
I'm well on my way re-building my '89R100gs/pd. Recently had the frame star-blasted (better than sand-blasting) and i'm ready for powdercoating, but first i want to gusset the frame HPN style. Could someone send me a link with photographs, or give me a detailed commentary on where these gussets should be placed. I'm guessing they would go near the steering head, where the main backbone is flanked by the two down-tubes, only i'm afraid of getting in the way of the path for the wiring harness. Also, is gusseting recomended near the back of the frame at the swing-arm? I will not be extending the swing-arm or front forks, so i'm still debating if this is all necesary?? Thanx in advance!!

**Grant Johnson** · #2 2 Jul 2004

Gusseting at the rear is probably unneeded, EXCEPT for the shock mount.

Front is RARELY needed - only have immediate knowledge of one broken frame by an overlander. Right behind the steering head...

Kevin Beretta has some pics here of his.

Note that it is important that the gussets are welded to the SIDE of the tube, not edge on to the tube. i.e. if you are going to gusset two tubes that come together, you could do a very small triangular piece that goes nicely in-between - but that is very weak, the tube will tend to crush in compression or tear in extension. Kevin's are done right, so look at the pics, also of course all the factory gussets are done right!

To get a better view, download and tweak in Photoshop or PSP, as they are too dark and contrasty to really see well.

Have fun,

------------------
Grant Johnson

Seek, and ye shall find.
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One world, Two wheels.
www.HorizonsUnlimited.com

**Frank Warner** · #3 2 Jul 2004

I've seen two frames brake between the top shock mount and the swing arm pivot. Some more strenght in that area is needed.

**nobby** · #4 5 Jul 2004

hi ron
if u send us your e-mail I can scan some photo's and send them to you hope your well

take care nobby

**Mr. Ron** · #5 6 Jul 2004

Hello.
Well, i did it! I took a perfectly good frame and welded the piss out of it!! Here's an up-date: I gusseted the rear shock tower using 1" square tubing (just like Kevin's photos) and i also added another flange where the left sub-frame strut attaches to the main-frame

Another gusset was welded into place near the steering head, connecting the main backbone to...well, look at the photos of Kevin's bike in the link above, it easier than explaining. Now here comes the good part...i welded a large gusset between the left footpeg and the frame, therefor providing me with a solid pickpoint to attach a bar to the back of my previously fabricated CrMo sub-frame

This will provide ample strength and use of the stock muffler.
Thanx for all your help everyone!