The turd

[1978GS750E]

Looking good!

[chuck hahn]

long way to go still

[chuck hahn]

I gotta take some pics and a little video of it running, started it today. I hung the pipes but didnt put in the new exhaust gaskets and ran it for maybe 2 minutes..

[chuck hahn]

So the last few days ive been doing little stuff while waiting on parts. One thing was figuring out a way to repair those 1 inch holes drilled into the tail cowl. I decided to use some body panel patch so there would be something with teeth for bondo. I took a burr and made a ditch on the inside around the holes and cut a piece of patch and then filled the ditch with JB Weld Plastic Welder and this fully seals the patch in place. Now its bondo ready.
And heres a little video from this morning. I promise you the engines quiet as a mouse when you put your ear close...once i make new pipes and put gaskets in it will be "normal" sounding again.

https://www.youtube.com/watch?v=KiYdGsT-qq8

Tail cowl repair preps...

[chuck hahn]

This afternoon i got the rear brakes bled, new reservoir and new cap installed for front brakes, started it again to do another heat cycle on the engine paint, troubleshot a faulty left hand switch as it kept blowing fuses whenever i out it on the bars but worked when not on bars. Turned out that a tiny spot of solder to the switch that turn dash lights on and off was making contact with bars and causing a short.

Then i got the service manual out to find out what wires went to the signals and plugged them in and tested. Put new bolts and gaskets in the bottom of the forks and filled the fork oil ( bought a pour rite cup to measure accurately ).

[chuck hahn]

The patch work on tail cowl went as planned and all is wet sanded to perfection. Also got the seat trim and one side cover wet sanded. I have a few knicks in the seat pan i need to fill once it dry.

[chuck hahn]

Other than these few things, the turd has been successfully polished. Decal set arrived today and i have all plastic parts wet sanded and ready for sealer. So heres whats left:

REHAB AND PAINT SEAT PAN
PUT SEAT COVER ON
INSTALL AIRBOX
SYNC CARBS
GET BANJO BOLT CRUSH WASHERS FOR FRT CALIPERS
PUT CHAIN AND SPROCKETS ON
STRIP TANK FOR PAINTING
INSTALL SEAT LATCH
PAINT BODY WORK

Its getting closer to done!!!!

[nvr2old]

Coming right along, Chuck. Everything has really shaped up since you started this project.

[chuck hahn]

AS SHE ARRIVED FOR SURGERY

[Cipher]

AS SHE ARRIVED FOR SURGERY

It looks like a solid bike not sure how you could cal it a turd.

[chuck hahn]

No fender, airbox, wrong seat, rusted out seat pan, 78 750 gauges, 1100 trim on the steering stem, ENTIRE front of wire harness chopped off, no signals, holes drilled into tail cowl, jury rigged with a push button for starter, no handlebar switches, literally everything covered in rust..and im sure im missing much more..

Pretty much fits my description of a turd.

[chuck hahn]

If you dont have cheese you dont have a sammich. How can you have a sammich if you dont have any cheese?

[ptegsotic]

If you dont have cheese you dont have a sammich. How can you have a sammich if you dont have any cheese?

I didn't feel like rankling the idiot. that's all.
again, great work. wish I had your skillz

[Buffalo Bill]

Soon as i find my camera...again, ill update with some pics. Today i did fork seals and polished the lowers, installed the wire harness,swapped out back rim and cleaned up the sprocket hub and all the hardware, applied Power Seal to all the bolts and newly exposed raw metals, and wrapped all the loose spots on the harness where it started to unwrap itself with some electrical tape, and mounted the gauges temporarily. IM TIRED!!!!

Wow! Replaced the fork seals, plus all that in one day?
I got a 2 bikes needing fork seals, about my dis-favorite job.

[chuck hahn]

Bill...it was like a ten hour day!!!! HA HA