1980 GS750L total rebuild from ground up to Cafe style

[NickyGS750]

Not too bad with the first run of electrolysis on the inside of gas tank for 24 hours. I just rinsed it out in the bathtub, lots of big flakes of rust poured out. Going to do another 24 hours and then ill dry it out completly, oil the outside, bag it up and itll be ready to powder coat once everything else is prep'd.

 

[NickyGS750]

Carbs disassembled and cleaned, bagged and tagged. Ready for soda blasting and powder coat. Simple green cleaner goes a long way!

 

[roeme]

Very interesting to see where the rust deposits; to me it corresponds roughly to where the tank insides are free of gas most of the time, exposed to the atmosphere (and hence, water). Assuming the stuff takes the shortest path.

 

[roeme]

Wait, these carbs haven't even seen an ultrasonic? They look hella nice.

 

[NickyGS750]

Very interesting to see where the rust deposits; to me it corresponds roughly to where the tank insides are free of gas most of the time, exposed to the atmosphere (and hence, water). Assuming the stuff takes the shortest path.

Was mostly mid and upper section. I agree, as long as there is fuel i think it does its part to prevent rust...i know in the summer months condensation happens above the fuel line. Thats why with every bike i owned i always had the tank full.

 

[Fjbj40]

Do yourself a favour, drill out the spot welds that hold on the emblems on the fuel tank. I can pretty much guarantee you the rust under there is close to perforation state. I have stripped multiple tanks and also removed them. After blasting there were holes.

It sucks if you don't and the tank leaks after you refinish it.

You are making great time so far!

 

[NickyGS750]

Wait, these carbs haven't even seen an ultrasonic? They look hella nice.

Nope, not yet... forgot to mention after the soda blast they will get ultrasonic for good measure.
Yup simple green cleaner is the best... for my anyways haha

 

[NickyGS750]

Do yourself a favour, drill out the spot welds that hold on the emblems on the fuel tank. I can pretty much guarantee you the rust under there is close to perforation state. I have stripped multiple tanks and also removed them. After blasting there were holes.

It sucks if you don't and the tank leaks after you refinish it.

You are making great time so far!

Yes thats part of the plan, lots to always mention... i appreciate it, lots of fun getting this done!

 

[roeme]

Do yourself a favour, drill out the spot welds that hold on the emblems on the fuel tank. I can pretty much guarantee you the rust under there is close to perforation state. I have stripped multiple tanks and also removed them. After blasting there were holes.

It sucks if you don't and the tank leaks after you refinish it.

You are making great time so far!

This sounds like an issue I might be up against soon; so: Spot welds holding emblems? Could you maybe provide pictures on where/what/how?

Edit: not necessarily in this thread, don't want to detract from Nicky's fine work log

 

[NickyGS750]

This sounds like an issue I might be up against soon; so: Spot welds holding emblems? Could you maybe provide pictures on where/what/how?

Edit: not necessarily in this thread, don't want to detract from Nicky's fine work log

I got you!
Circled in red... just drill them out (carefully!) And itll come right off

 

[NickyGS750]

Productive day... cleaned carbs, stripped some painted pieces (took awhile on these for some odd reason, paint just didnt want to come off)
And started a new batch of electrolysis on about 20 parts crammed into (not touching) into a little tub. Finished up electrolysis on the fuel tank... and now going to attempt to remove emblem brackets on fuel tank to get after that rust.

20 parts in tub

Stripping paint on calipers, engine mount and front peg brackets.

 

[Fjbj40]

Yummy, paint stripper! What you going to spray them with? Do you have a blast cabinet?

Zipping right along you are :applouse:

 

[NickyGS750]

Yummy, paint stripper! What you going to spray them with? Do you have a blast cabinet?

Zipping right along you are :applouse:

Ya, horrible stuff... but gets the job done. Itll be with a baking soda media. No cabinet, since soda is cheap and washes away i just do it outside of my shop.
Sure am! Want to get all the preping done as soon as possible... over and done with

 

[Sam 78 GS750]

Looking really great! Quick question on the electrolysis for the tank. How do you dry it out to prevent flash rust? WD40 and then compressed air? Another method?

 

[NickyGS750]

Looking really great! Quick question on the electrolysis for the tank. How do you dry it out to prevent flash rust? WD40 and then compressed air? Another method?

Thank you! I generally use BP blaster for flash rust, same with storing parts wrapped in plastic. Wd40 works great too. Compressed air and let it sit in front of a heater on low. Another trick i learned was to hang a silica bag inside it, just another way to help pervent moisture especially if you seal up the tank.

 

[NickyGS750]

Did a little debadging on the gas tank. Those things were really on there. Figured id be drilling through the tank, even being careful it actually happened. I might just end up cutting that dented section out and tack/weld a new piece in it, lots of the rust pitting.
Also that rust jelly sure doesnt work like it used to... im going on 5 coats on each side so far...

 

[NickyGS750]

So many little parts to keep track of, tedious cleaning... i cant be the only one who hates all these phillip head screws on these bikes... one major thing im changing... all the phillips screws into hex... make life easier.

 

[Guest]

They aren?t phillips head screws if they are stock. They are JIS. Get some good JIS screw drivers & you will like them a lot more.

 

[NickyGS750]

They aren’t phillips head screws if they are stock. They are JIS. Get some good JIS screw drivers & you will like them a lot more.

True... i did happen to find out they were JIS screws 3/4's through the tear down of the bike, was a little too late then haha.
But ya every JIS screw will be replaced with a Hex. Lot of screw measurements to write down....
At least there is a hex set for the carbs already at z1.

Scratch writing down measurements haha... literally just found a complete hex set on ebay
https://m.ebay.com/itm/SUZUKI-GS-750-E-L-G-GL-1976-1981-Engine-stainless-allen-screw-kit-2-GS750-/121792632178

 

[Fjbj40]

Use Hoppes#9 bore cleaner for your brass carb parts, you will never get them cleaner! Rinse with IPA after, not IPA beer though, that's to enjoy while they are soaking