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Like a hole in the head...

Still wanted to get a bit more done, so I repainted the master cylinder and brake caliper, which also had road rash across the flat surface of the face, and yet no scratches on the fork leg..weird. I got a flat file and some 80-180 grit sandpaper out and removed them and then smoothed up the shoulder around it, too. Looks pretty nice now..



I also stripped that crappy old clear plastic off the levers and removed the rubber ends and then took a scotch brite pad and aluminum polish to them.



Got the carbs cleaned up. I'm polishing all the aluminum bits, but not like chrome. I want all the pieces to look a bit aged, but yet, well taken care of....hmm..does that make sense ..:D The outside bowl is done.



Maybe too many paint fumes, but the choke butterflies look like emoticons to me..





Back on the bike with the air box, horn, cables and coils.





Pretty close to done with the front end except for the turn signals which need to have their mount repainted and the headlight shell which needs a bit of repair and then on to the battery box and air filter, wiring harness and back end. Piece at a time, Larry, piece at a time..



 
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I often forget that it takes 5 times as long to re-assemble things as it does to take apart. No cleaning, polishing or painting involved in dis-assembly.:rolleyes:

I wanted to get the rear wheel put back on this weekend, so I grabbed all the parts to do it and they all needed work.

The left side isn't too bad, just needs to be cleaned and the sprocket cover re-painted.





The brake side's not too bad either, really..but I can't leave it alone.



Sanded it with 180-220-400-600-1000 then just polished by hand. I don't want it too shiny. I like this look.





The axle, chain adjusters, spacers, brake rod and stay were nasty. Should've taken some before pics but I didn't. Lots of corrosion that needed to be removed, then everything polished.



Again, should've taken a before pic. The headlight shell had a chunk missing about an inch long and a 1/4" deep broken off the front edge. Just formed it in 2-part epoxy, sanded it smooth, primed and painted. Good as new.



Crazy as it seems, four hrs. to get these parts (and the rear wheel) ready to put back on. Took about 20 minutes to pull them off the bike..:D



More assembly tomorrow before the football games begin..
 
Ohhh..I should be able to re-assemble that thing in just a couple of days....mm hmm..:rolleyes: Two weeks later, it's finally back together.



It'll probably never be this clean again.





I'm anxious to throw a battery in it to make sure all the wiring is correct. It should be..everything's color coded. I have to wait till I can button up the headlight bundle. I'm dumping the gargantuan stock turn signals for these..front and rear



The stock turn signal mount is also the headlight mount so I ordered some of these, too, from Dime City..should be really clean looking.



I also got this on eBay. I really like the look of it.



LED bulbs, license plate light and plate holder all in one..for $21..cool!

 
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While I wait for that stuff to get here I thought I'd get the exhaust and this oil filter cover repaired. Someone took a hack saw blade to this cover..wtf..right across the fins..? The dark gray line is where I filled it with JB Weld.



It also had the whole outside corner fin broke off, so I made one out of JB Weld.



Some sanding and a couple of coats of silver..not bad.





Even though I got the collector looking better then this last summer..



The holes bugged the s--t out of me so, yes..more JB Weld..



Some more sanding and a few coats of "chrome silver" header paint..





For something you have to get down on your hands and knees to see, I can live with this..I'm pretty happy about the results. Can't wait to put it back on the bike tomorrow night. Body parts start next week..cool..
 
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Knowing the scarcity of those head pipes your work on the collector portion is terrific.
I did not know that chrome paint looked so good.
 
Daaaaaang, I wish I had been following this thread sooner. Your work on these cosmetic issues is amazing. I didn't know JB Weld was this versatile! :)
 
Thanks, man. I learned many years ago that JB Weld is an amazing product. Almost anything metal can be repaired with it..(within limits..) It's especially nice for engine parts because it's so heat resistant. You can sand it, tap threads into it, paint it..pretty cool stuff, for sure. Liquid Steel, and Cold Weld do the same thing.
 
steve murdoch said:
Knowing the scarcity of those head pipes your work on the collector portion is terrific.
I did not know that chrome paint looked so good.
Click to expand...

I agree, Steve. it turned out way better then I had anticipated. "Chrome Silver", eh..? Yeah, right..but, it really does have a chrome-like reflection to it.

I looked for months for a decent replacement header, and the crazy prices people are asking for total rusty and/or dented pieces of crap, pushed me to this repair. The pipes are beautiful, so overall it looks much, much better now.
 
Got the exhaust back on last night. Starting to look like a motorcycle again.







Thanks again for the interest, you guys.
 
I finally got everything buttoned up on the frame and engine this weekend. Really feels good. I stuck a battery in, turned the key, and everything seems to be working..yaaay. For someone whose done this completely solo for the first time, I'm pretty stoked. :D

Love the new turn signals..so much cleaner then stock.



I re-painted the exhaust flanges and replaced the regular 6mm nuts with some chrome castle nuts. A subtle thing, yeah, but it looks really finished.



I spent about five hours yesterday cleaning and detailing the front end. I repainted the guard and the centers of the rotor, I filed off all the castings around the bosses on the forks and then sanded them down from 80 grit-800 grit and polished them by hand. Man, they're smoooth. ;)





Pretty happy with the results.





Time to jump on the tank, tail section, fender, and side covers.
 
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