Blue 78 1000C project

[nvr2old]

It's only a matter of time and confidence..The side covers are easy. The tank is a bee-otch, though..

 

[busa1300]

Looks great, glad I could help
I've been painting for over 35 years, and taking your time is definitely a necessity to only having to do it once.

 

[Kiwi Canuck]

I am 110% certain ALL the Kreem has been removed. Fire...the tool of choice when youve just had enough and patience is gone!!!

This gives "Fire up the Bike" a whole new meaning.

Looking good chuck.

David

 

[chuck hahn]

Rained all day so painting was out of the question. Switched gears and mounted the battery box, electrical panel, and both handlebar switches. Didnt repaint the switch housing but I did redo the lettering. Took the back off the fuse box so I could remove the terminals and clean those as well. Reassembled fuse box and mounted it and the starter selinoid.

Got the Veshra gasket kit so tomorrow will be all day on the engine. Should have it buttoned up by the evening. Soos as the rain goes away the engine will get painted..which looks like sometime next week here in OK.

Probably take a few pics tomorrow.

 

[chuck hahn]

Set the top end today, lapped the valves, adjusted all the valves, scrubbed the scale off the fins on the head, painted the recesses where the plugs go in so its easier when painting the complete engine. Short of getting the new half moons for the cam ends, cleaning the engine, and repainting it the engine is about done. Of course i still have to clean the oil pickup screen and polish the covers.

 

[chuck hahn]

Got a weekend without rain so I got after the body work again today. Wet sanded the tank and laid my home made sky blue side stripes and the pinstripes from the Reproduction Decals Kit. Shot color and 1 coat of clear on the tail cowl and wet sanded the seat trim. Gonna lay the decals on the tail and wets sand everything. Then it all gets the final clear and done. After this will be fix a broken tab on the left side cover and paint them black with 2 coats of clear.

 

[chuck hahn]

While letting the body work rest I took the engine outside and got after it with all different size brushes and 2 spray bottles of simple green. Took all of 2 1/2 hours to degrease the thing. Fired up the compressor and blow dried it well and then let it air dry a while. Laid it over onto the clutch cover and painted the oil pan and as much as i could get at. Since its drying on its side for the night first thing I will do tomorrow, before flipping it upright, will be to drop the pan and clean the oil pickup screen. New gasket and button it back up.

Once i get it all painted I will snap pictures. First order of business will be final wet sanding and final clear of the body works before my hands get all dirty. Then the engine.

 

[chuck hahn]

So today was finish painting the engine day and do the last clear on all the body parts. I took off then pan to clean the pick up screen as they are usually nasty. But i was shocked to see it was perfectly clean and only a little residue in the pan itself. The inside of this engine is super clean and shiney like it was assembled yesterday!! No joke..its stunningly clean actually. clocks show 24,660 miles. So heres the engine and a few shots up inside the transmission area. Note that the oil screen is exactly how it was when I took off the pan. I simply rinsed out the pan with some carb spray and put the new gasket in and walked away.

 

[chuck hahn]

Nothing super exciting today. Got the pipes down off the wall and shined them up decently. Lots of light surface rust on the tops of the pipes and around the cross over but the polish and a SOS soap pad made fast work of it. Gonna set the engine in and get the pipes mounted tomorrow after work

EDIT---- Got a thick piece of plastic attached to the area of the missing tab on the left side cover. I super glued it into place and then used a 3/8 burr in the die grinder to make a ditch and filled it with Devcon Plastic Welder It will be stronger than the original one probably. I will take pics of that repair as it goes too.

 

[thebrandonbeezy]

This is gonna be a beautiful bike

 

[chuck hahn]

I think its gonna look sweet as heck. I have a new set of the old style stator and points cover emblems i have had wrapped up in tissue paper for years that are gonna go on the covers. once the engines back in the frame I will get after polishing all the covers..clutch, stator, points, and sprocket. And of course the fork lowers will get done when i break them down to do the fork seals.

I got a really nice seat from Steve ..I think. Pans near perfect and it has a nice Saddleman cover. Its a stepped seat but I think someone once said the Euro models had stepped seats?? Anyway, it will be the saddle till I can get a Pit replica cover and reshape the foam.

 

[nvr2old]

You're moving along at an admirable pace, Chuck. I've enjoyed watching your progress. It's gonna be a nice one, for sure.

 

[chuck hahn]

Set the engine and hung the exhaust tonight. Sat the body work and seat on just for some photo ops. Still gotta finish making a tab for the left side cover and get the covers painted Black. Most of the heavy and tedious stuffs done now. Its a matter of adding bits and piece here and there now. Still plenty to do but the pics give it some resemblance as to what the end will look like.

 

[1978GS750E]

Very nice! And the best part.........another one saved from the sawzall!!!

 

[Guest]

Looks awesome, Chuck.
Keep up the good work!

 

[chuck hahn]

Started on fashioning a tab for the broke side cover. Not the prettiest thing in the world but it will hang the cover on the bike. The pics show the plexiglass glued to the cover with the Devcon Plastic Welder, then the sharpie line for me to drill a series of holes and hog out a rough slot, then after some filing with a flat file. Still gotta shape it a little more but you get the idea.

Also I have had these NOS stator and points covers wrapped in tissue paper for all of years waiting to be on this bike...Gonna look nice!!!

 

[Big T]

Chuck, the stator cover is for a newer model, as you can see

 

[chuck hahn]

Yes, but its all I have and its way better than whats there. Im also thinking about getting the allen head cover screw kits as well so its not gonna be a 100% technically correct deal. Wish they had done allens from the factory as these JIS screws suck.

 

[chuck hahn]

Anyone know of a vendor for the allen head engine cover bolt kits???

 

[portdave]

https://alloyboltz.com/product/suzuki-1978-1980-gs1000-chain-drive-polished-allen-engine-kit/