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I was looking for a winter project.........I found this!

1978GS750E said:
Well today I got the tank cleaned, as well as I could. Lots of dried up fuel and rust. Attempted to order a Caswell Epoxy kit but they are out of stock until 11/30/22, per their website.

Can't even place an order for it, which seems strange! (Wanted to get the 15% off for their Black Friday sale.) Those kits are getting expensive!

Oh well, guess I'll order it on Wednesday.

Working on cleaning up the fuel level sending unit now. Then will work on the gas cap! Then on to the brakes, tires, forks, electrical ..........
Click to expand...


You might want to try to derust before going straight to a liner. Get some phosphoric acid. Kleen Strip Concrete and Metal Prep from Home Depot. Fashion some good plugs first, though. Don't use the sending unit, petcock, and gas cap. And let the tank vent, because it will outgas. Dilute to fill the tank and it will be rust free in an hour or two. You can't derust through varnish, though, so be sure to get all that out first.
 
Nessism said:
You might want to try to derust before going straight to a liner. Get some phosphoric acid. Kleen Strip Concrete and Metal Prep from Home Depot. Fashion some good plugs first, though. Don't use the sending unit, petcock, and gas cap. And let the tank vent, because it will outgas. Dilute to fill the tank and it will be rust free in an hour or two. You can't derust through varnish, though, so be sure to get all that out first.
Click to expand...

Sorry, I should have said that I "derusted" the tank! Added a gallon of vinegar and about 100 drywall screws, then shook it off and on for about an hour to loosen the varnish and rust. Rinsed with water and then used the Kleen Strip. Then rinsed with a baking soda solution to neutalize the acid. Then dried it with compressed air.

I've done a few tanks in my time, (being an old fart), so I have fashioned aluminum covers that I fit over the fuel sending unit and petcock openings. I've found that aluminum tape that HVAC guys use does a good job on the filler hole.

Should be ready for the liner now!
 
Last edited:
"Shook it for a hour"... Should have rented a cement mixer to do the job. Haha. Who did that? Someone around here I think. Chuck maybe?
 
1978GS750E said:
Sorry, I should have said that I "derusted" the tank! Added a gallon of vinegar and about 100 drywall screws, then shook it off and on for about an hour to loosen the varnish and rust. Rinsed with water and then used the Kleen Strip. Then rinsed with a baking soda solution to neutalize the acid. Then dried it with compressed air.

I've done a few tanks in my time, (being an old fart), so I have fashioned aluminum covers that I fit over the fuel sending unit and petcock openings. I've found that aluminum tape that HVAC guys use does a good job on the filler hole.

Should be ready for the liner now!
Click to expand...

Excellent. Sounds like you know your way around a project like this one. Only comment, I'd try to avoid the liner, unless the metal is thinned out from rust. That phosphate sauce WILL eat off all the rust, you just need to give it enough time. Only worry with that stuff is if you leave it in too long, a whitish passive coating starts to build up. Also, Caswell's is killer thick. Works great to reinforce thin metal. Even at that, I'd thin the stuff because it doesn't flow for crap. POR-15 works good too, and is easier to apply. It doesn't reinforce, though.
 
"Really snazzy windscreen"!

Do dorky sellers realize that only attracts dorky buyers? Besides, the extra aerodynamics are needed to make up for the dragging understand! :uncomfortableness:

Glad to see they're going up in value. In 2013 I saw mine advertised for $1900. When it was lowered to $1500 three weeks later, I pounced. 24k miles in EXCELLENT running order! :cool:
 
Rob S. said:
"Really snazzy windscreen"!

Do dorky sellers realize that only attracts dorky buyers? Besides, the extra aerodynamics are needed to make up for the dragging understand! :uncomfortableness:

Glad to see they're going up in value. In 2013 I saw mine advertised for $1900. When it was lowered to $1500 three weeks later, I pounced. 24k miles in EXCELLENT running order! :cool:
Click to expand...

What are you trying to say there Rob, since I bought it? It took a total of about 5 minutes to remove that really snazzy windscreen!:p

Do you mean "dragging centerstand"? That was due to a weak spring since it had been sitting on it for 18 years.

Hopefully it will be a keeper, once it is finished. Besides I need something to do in the winter, instead of sitting around reading stuff on internet forums!:rolleyes:
 
Things like that windscreen and dragging center stand, that do make it look a little worse, are a plus when buying, just makes the price a little cheaper while no problem to quickly, easily, and cheaply get taken care of...
 
1978GS750E said:
What are you trying to say there Rob, since I bought it? It took a total of about 5 minutes to remove that really snazzy windscreen!:p

Do you mean "dragging centerstand"? That was due to a weak spring since it had been sitting on it for 18 years.

Hopefully it will be a keeper, once it is finished. Besides I need something to do in the winter, instead of sitting around reading stuff on internet forums!:rolleyes:
Click to expand...

ZERO offense intended. And yeah, that darn spellchecker. :mad-new: Centerstand.
 
What IS it with all the discarded airbox lids?

Did any of these things make it out of the '80s with their airbox lids? I can't recall ever seeing one.
 
bwringer said:
What IS it with all the discarded airbox lids?

Did any of these things make it out of the '80s with their airbox lids? I can't recall ever seeing one.
Click to expand...

All the 4-into-1 pipes came with instructions to "Remove the airbox lid. No carb modifications needed."

And yes, I have seen one. Actually, it was a photograph of one. But it was very graphic. :rolleyes:
 
Dang it, where did them lids go??? I know there were several of them laying around here!!! ...Oh yeah, that was 40 yrs ago.
 
bwringer said:
What IS it with all the discarded airbox lids?

Did any of these things make it out of the '80s with their airbox lids? I can't recall ever seeing one.
Click to expand...

Guess I got lucky, as both my 78 GS1000 and 81 GS1100 have them.:cool: Maybe I'll have to swap a lid to which bike I'm going to ride that day!:-k

Wait, this bike is going to have an aftermarket exhaust, I'd just have to throw it away if it had one!:rolleyes:

Like Meatloaf said, "Two outa three ain't bad!":p
 
Santa showed up early at my house. Brought me this fine Delkevic exhaust system. ( Still don't understand why he was wearing a UPS uniform???):biggrin-new:

0EkmOs4.jpg
I will have to say that this system looks to be of very high quality. Can't wait to hear it!
 
Last edited:
1978GS750E said:
Santa showed up early at my house. Brought me this fine Delkevic exhaust system. ( Still don't understand why he was wearing a UPS uniform???):biggrin-new:

0EkmOs4.jpg
I will have to say that this system looks to be of very high quality. Can't wait to hear it!
Click to expand...

Is it as gold as it appears in the pic? Is it my eyes?
 
No, its a shiny silver stainless steel!

Might be the light in the room, your monitor, or it could be your eyes!:p
 
Good looking pipe Ron. You'll have to do a video of it's sound when you get it running. I've heard they are quite loud. Badass would be a better term.
Anxiously waiting to see and maybe ride this beast.
 
alke46 said:
Good looking pipe Ron. You'll have to do a video of it's sound when you get it running. I've heard they are quite loud. Badass would be a better term.
Anxiously waiting to see and maybe ride this beast.
Click to expand...

You mean you like it better than the pipe that came off of it?

Special 3 piece Vance & Hines Exhaust: At least the baffle was intact, about the only thing on it that wasn't rusted through!

WcO3eQx.jpg
 
Making some progress on it!

I'm refurbing parts as I remove them. Already have the tank derusted and the headlight, side covers, rear cowl section, taillight, turn signals, air filter housing and a few brackets ready to go back on when the time comes.

This is how it looks today:

awdHCfm.jpg
 
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