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Progress!!! 1978 GS1000E Restoration/Performance Rebuild

JTG - (continued post, more costs)

Various buckets and measuring cups from McMaster Carr: $30
Muriatic & Sulfuric acids: $20
Misc Supplies & Distilled water: $20
Copper wire: $10

GRAND TOTAL FOR THIS SECTION: $80

Where I didn't spare the expense - and some do - is the constant current plating rectifier. Some people jig rig batteries, light bulbs, and rheostats to achieve the proper current for plating. I had zero desire to do any of that, so I purchased the rectifier from Ebay. Attach the leads, set your current, and the power supply manipulates the voltage to maintain your set current. Easy as pie, and worth the $60 in my opinion.

Although $300 for a proper plating setup may seem expensive, there are numerous parts on our bikes (brackets, chain adjusters, spacers, axles, etc) that either aren't available anymore or buying them new is very expensive. Buying a new axle, chain adjusters, and spacers, can easily be $150 or more. The setup pays for itself quickly.

Although the chemicals from Caswell work great, I wouldn't buy any of their other kit supplies such as anodes, power supplies, etc. Equivalent items can be found for far cheaper, especially the anodes, on the internet. Rotometals.com is an EXCELLENT source for large zinc anodes with an integral copper wire. Caswell will charge you an arm and a leg for a flimsy sheet of zinc.

Overall, I'm actually enjoying the hell out of plating stuff - I'm like a kid with a new toy!!! In a weird way, its fun!
 
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I have drooled quite a bit over this thread and I just realized you're in Aurora, IL. I would LOVE to see the bike when you're done, it looks amazing so far. I'm in Loves Park (Rockford area).
 
Engine assembly, splitting/joining the cases to properly install seals, ROUND 2... (arrgh, waves fist in indignation at motor :miserable:)

IMG_1286 by Anthony Monteleone, on Flickr
IMG_1288 by Anthony Monteleone, on Flickr
IMG_1289 by Anthony Monteleone, on Flickr





IMG_1287 by Anthony Monteleone, on Flickr
IMG_1290 by Anthony Monteleone, on Flickr

IMG_1292 by Anthony Monteleone, on Flickr
IMG_1291 by Anthony Monteleone, on Flickr
IMG_1293 by Anthony Monteleone, on Flickr
IMG_1294 by Anthony Monteleone, on Flickr
 
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I was looking at the detail in this rebuild and it struck me... What do you intend to do with this bike with it's done? Show piece or a daily rider? All this work on the cosmetics and one rain storm... You get what I'm saying? Just curious as to where this project will end up.

On my bike I kept the detailing to a minimum just because I didn't want to see all my work go south by using the bike for what it was intended... RIDING!!!:)

Don't get me wrong here. I admire the work you're putting into this project.
 
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I was referring to all of the detailed cleaning and newness that gets... well... less new. Once you've begun to ride her she'll never be as perfect as the day you first put her on the road. After a ride in the rain (at least here in Georgia) you can spend hours trying to get all the road grime off, but you'll never be completely successful. I guess it's a little like right after buying a new bike. Except in your case you have much more hard earned blood and sweat involved. Maybe a little like getting that first door ding on the new car. The next ding doesn't seem to feel as bad.;)

Great job so far!
 
I was referring to all of the detailed cleaning and newness that gets... well... less new. Once you've begun to ride her she'll never be as perfect as the day you first put her on the road. After a ride in the rain (at least here in Georgia) you can spend hours trying to get all the road grime off, but you'll never be completely successful. I guess it's a little like right after buying a new bike. Except in your case you have much more hard earned blood and sweat involved. Maybe a little like getting that first door ding on the new car. The next ding doesn't seem to feel as bad.;)

Great job so far!

Thank you sir :-) As for detailing and maintenance, I have a 2007 FZ6 that still looks like its new - I go overboard on maintenance and cleaning. Perhaps that was evident in the meticulousness of this restoration :D
 
I just want to be able to find this thread again, along with its links.Tons of valueable info.
 
Small parts - BACK FROM THE POWDERCOATER!!!










Very nice job on the powder coating, did you tape all the threaded parts or will you need to chase the threads out?

I didn't see the battery box in that batch, did you get it done as well?

Also what is the item in the top left, looks like it's fender related but I don't recognize it.

Cheers,

David
 
This bike is going to look like a million bucks.

Thanks for the detailed write-up on the zinc plating. I have a feeling that's something I'm going to dabble in one day. How long do you expect the plating to hold up against corrosion? (I'm sure it depends a lot on how clean the bike is kept, local humidity, etc.)

Those $60 eBay power supplies work but are known to go kaput after a time. Some fail by delivering high voltage to the output with spectacular results. Not saying yours will but if it were me, I wouldn't leave it unattended for too long. :) Unfortunately I don't know what the best buy in power supplies is right now because I'm still trying to figure that out myself.
 
Very nice job on the powder coating, did you tape all the threaded parts or will you need to chase the threads out?

I didn't see the battery box in that batch, did you get it done as well?

Also what is the item in the top left, looks like it's fender related but I don't recognize it.

Cheers,

David

David - my powdercoater may cost a few extra $$$, however, he faces and chases EVERYTHING. Also, his masking, taping is 2nd to none - I rarely have to clean goo out of threaded holes, etc.

The part in the upper left is a metal fender support - I'm going to be running a front fender from a later model 1100E. As for the battery box, it's going to wait until the end because I am still modifying/welding/chopping it to make mounting surfaces for my R/R, main charging fuse, keyswitch fuse, and main fuse. I'm going to be adding 3 relays to the system (horn, ignition coils, and main) and an updated blade-style fuse panel.
 
This bike is going to look like a million bucks.

Thanks for the detailed write-up on the zinc plating. I have a feeling that's something I'm going to dabble in one day. How long do you expect the plating to hold up against corrosion? (I'm sure it depends a lot on how clean the bike is kept, local humidity, etc.)

Those $60 eBay power supplies work but are known to go kaput after a time. Some fail by delivering high voltage to the output with spectacular results. Not saying yours will but if it were me, I wouldn't leave it unattended for too long. :) Unfortunately I don't know what the best buy in power supplies is right now because I'm still trying to figure that out myself.

The corrosion resistance of the zinc plating depends on it's thickness - zinc is sacrificial, thus, the more zinc on a part the longer it will hold up before the base metal corrodes. I'm plating my parts for around 20min, which should be between .0005 and .001 of plating. I haven't been measuring before/after of each part with a caliper :p

As for the power supply - I will keep an eye on it. I only run it for 20min at a time, moreover, I don't run it at maximum, either - 4A, which is 80% of it's maximum current of 5A is the highest I will go. 4A will plate quite a few parts. My biggest batch usually runs around 2.5 to 3A.

With that being said, having a CC rectifier for zinc plating IS the way to go. It removes an element of guesswork from the equation, and it just makes life easier.
 
I can see the light at the end of the tunnel - MORE PROGRESS! Cylinders, head, and cams installed. Cam timing and buttoning up the remaining parts of the engine to follow.

101 by Anthony Monteleone, on Flickr
11 by Anthony Monteleone, on Flickr
12 by Anthony Monteleone, on Flickr
13 by Anthony Monteleone, on Flickr
14 by Anthony Monteleone, on Flickr
141 by Anthony Monteleone, on Flickr
15 by Anthony Monteleone, on Flickr
16 by Anthony Monteleone, on Flickr
17 by Anthony Monteleone, on Flickr
171 by Anthony Monteleone, on Flickr
 
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Hey, looking good.....Don't forget your cam chain guide (between the cams) and liberal amounts of MOS2 for the cam lobes and adjustment shims......And word of caution, don't install the tach drive until the exhaust cam is bolted in.....Billy
 
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