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SuzukiSavage.com
/cgi-bin/YaBB.pl General Category >> Rubber Side Down! >> The project begins /cgi-bin/YaBB.pl?num=1291033483 Message started by MotoBuddha on 11/29/10 at 04:24:43 |
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Title: The project begins Post by MotoBuddha on 11/29/10 at 04:24:43 I picked up this "beauty" Saturday. A '96 that had been sitting exposed in a carport for a couple of years. It sort of ran when I went to see it. I thought at the time it was probably a dirty carb. The saddlebags were rotting and the lovely skull stickers were peeling. It was sort of a rescue mission. http://i280.photobucket.com/albums/kk182/motobuddha/c65b0398.jpg http://i280.photobucket.com/albums/kk182/motobuddha/cb0913b9.jpg The one-of-a-kind (I hope) custom exhaust flapped around, held on by a single drywall screw inserted (not threaded) into a hole. http://i280.photobucket.com/albums/kk182/motobuddha/1cc70440.jpg But now it's stripped down and I'm looking for someone to help get the engine back in shape. There was gas in the airbox and intake, and when I drained the oil, it was mostly gas. At least the crankcase got a good flushing. http://i280.photobucket.com/albums/kk182/motobuddha/d8dfc9b7.jpg |
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Title: Re: The project begins Post by serenity3743 on 11/29/10 at 05:20:32 Gas in the places you talked about could be just a petcock problem, solved by replacing with an OEM (my preference) or a Raptor (several other people's preference). How many miles on the bike? |
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Title: Re: The project begins Post by MotoBuddha on 11/29/10 at 05:47:02 I know about the petcock problem (among other chronic LS650 issues). It's on the list. It has 8757 miles on it, which could be a low mileage cream puff, or a bike that has been neglected and abused. There were kludge patch jobs here and there that make me less than totally optimistic. We'll see when we open it up. |
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Title: Re: The project begins Post by justin_o_guy2 on 11/29/10 at 10:16:00 6oo miles a year or so ?? Thats documented neglect. |
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Title: Re: The project begins Post by MotoBuddha on 11/29/10 at 10:35:31 6C7375726F6859695961737F34060 wrote:
It'll get more attention in the next few months than it had in the previous 14 years. |
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Title: Re: The project begins Post by Lupo on 11/29/10 at 10:47:39 I too did a rescue. My neighbor said why(?) when I brought it home. Now people walk up and ask questions about it. Lots of labor and very little money has been very rewarding. Have fun with that mutt. |
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Title: Re: The project begins Post by serenity3743 on 11/29/10 at 12:55:50 5E7C677C516677777B72130 wrote:
What is "kludge"? |
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Title: Re: The project begins Post by Edgar on 11/29/10 at 13:11:10 It'll be a fun project. Well worth it. |
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Title: Re: The project begins Post by verslagen1 on 11/29/10 at 13:59:18 6B7D6A7D76716C612B2F2C2B180 wrote:
What is "kludge"?[/quote] Think ratbike. |
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Title: Re: The project begins Post by MotoBuddha on 11/29/10 at 14:06:55 594F584F44435E53191D1E192A0 wrote:
A kludge is a patch job, usually not done well, with questionable materials, and almost always ugly. Examples on my bike -- -- muffler held on with a drywall screw inserted in a hole -- end of throttle cable held onto the carb with a piece of knotted wire For more examples, you might want to visit this site: http://thereifixedit.failblog.org/ |
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Title: Re: The project begins Post by Daeldren on 11/29/10 at 15:48:15 I think I almost went to see that particular bike, did you buy it from a lady? Looks like a good project bike for sure can't wait to see her when she is done. |
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Title: Re: The project begins Post by MotoBuddha on 11/29/10 at 16:40:36 Yeah, a lady near Hickory. Maybe you were the guy she said was coming up from SC last Saturday. |
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Title: Re: The project begins Post by Daeldren on 11/29/10 at 18:33:49 Yep that would be me, ended up picking the one up in charlotte instead, can't say it was a better deal seems like both bikes need some work but it could be worse for the money. That lady seemed a bit odd on the phone when I talked to her though. |
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Title: Re: The project begins Post by MotoBuddha on 11/29/10 at 18:52:43 Yeah, she was, um, unique. Her husband was a chatterbox. Well, good luck with the one you got. Was it the black one on Craigslist? |
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Title: Re: The project begins Post by Daeldren on 11/29/10 at 19:10:25 Yup, missing a bunch of stuff (key for fork lock, side covers, toolbox and battery cover, sissybar.) but she does run. Need to fix the plug leak in the top end and petcock is really nasty. |
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Title: Re: The project begins Post by dasch on 11/30/10 at 08:48:00 ...and fuel in the crankcase might be a sign of a bad carb float valve. OR a hole in the petcock membrane. Check both. This thing looks cleaner than mine. Enjoy it. |
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Title: Re: The project begins Post by MotoBuddha on 12/01/10 at 06:26:26 It certainly looks cleaner with the ugly tins removed, anyway. ;) I was looking at the carb last night and the slide was covered in black grime. And the butterfly had a scorched look to it. Could be the intake valve isn't sealing well. And that means the exhaust valve is probably in similar shape. For all I know, there could be critters living in the cylinder. Or Chilean coal miners. |
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Title: Re: The project begins Post by MotoBuddha on 12/05/10 at 05:12:58 I guess I'm beyond the point of a couple of small mods. http://i280.photobucket.com/albums/kk182/motobuddha/85d328bc.jpg |
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Title: Re: The project begins Post by justin_o_guy2 on 12/05/10 at 05:18:54 Well, at this point, its either gonna be a cool build or youve almost created a fine basket case. I hope youre able to dedicate the time you need to get it where ya want it by Spring. |
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Title: Re: The project begins Post by MotoBuddha on 12/05/10 at 05:48:16 I have another bike, so Spring isn't a deadline. |
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Title: Re: The project begins Post by MotoBuddha on 12/05/10 at 08:48:37 It's getting serious now. I just ordered up a gasket kit, carb rebuild kit, heavy duty clutch kit, some wheel and swingarm bearings... More to come, no doubt. |
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Title: Re: The project begins Post by MotoBuddha on 12/08/10 at 11:39:54 Mmmmmm, gaskets. Vacuum packed for freshness and extra flavor. http://i280.photobucket.com/albums/kk182/motobuddha/ff364110.jpg |
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Title: Re: The project begins Post by MotoBuddha on 12/12/10 at 08:47:57 No turning back now. http://i280.photobucket.com/albums/kk182/motobuddha/2d643e90.jpg |
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Title: Re: The project begins Post by justin_o_guy2 on 12/12/10 at 09:47:48 You gonna fill the gaps between gussets & tubing? |
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Title: Re: The project begins Post by MotoBuddha on 12/12/10 at 10:11:25 That's the plan. |
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Title: Re: The project begins Post by justin_o_guy2 on 12/12/10 at 10:23:40 How you plannin on doin that step? Weld & grind or bondo? |
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Title: Re: The project begins Post by MotoBuddha on 12/12/10 at 10:49:29 Since I'm going to powdercoat the frame, it'll have to be welded or brazed. |
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Title: Re: The project begins Post by justin_o_guy2 on 12/12/10 at 11:38:04 Yep,, thats a fact... I just got a torch & a bunch of Brazing stuff. Tried it out. Its pretty easy, I just cant see well, somehow, seems the goggles affect the glasses, everythings fuzzy. Makes me do a lousier job than I would if I could see better,, or so I will continue to claim,, |
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Title: Re: The project begins Post by MotoBuddha on 12/12/10 at 12:03:27 Can someone tell me what this tab is for? It's on the bottom of the swingarm, on the belt side. http://i280.photobucket.com/albums/kk182/motobuddha/695f52a0.jpg |
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Title: Re: The project begins Post by justin_o_guy2 on 12/12/10 at 12:44:58 Cant see that anything has ever been bolted on it. Looks like grinder fodder from here. |
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Title: Re: The project begins Post by verslagen1 on 12/12/10 at 12:52:12 It's either the tab for the belt adjustment tool (yeah it has a place to put it) Or the tab for bolting on the belt cover that been bent down. |
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Title: Re: The project begins Post by groupus on 12/12/10 at 12:57:40 that little tab is where you're supposed to put the belt tension measuring plunger thingy. its the gold colored spring-loaded thing that comes in the stock tool kit. if you don't have that tool, might as well hack it off. |
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Title: Re: The project begins Post by MotoBuddha on 12/12/10 at 13:32:30 Thanks. I'm converting to a chain, so adios to that tab. |
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Title: Re: The project begins Post by MotoBuddha on 12/16/10 at 18:03:58 More parts in. Carb rebuild bits along with fork caps and stem nut that aren't as scratched and rusty as the ones I had. http://i280.photobucket.com/albums/kk182/motobuddha/90941397.jpg http://i280.photobucket.com/albums/kk182/motobuddha/fe4b6a6e.jpg Anyone have some decent stock clutch and brake levers? |
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Title: Re: The project begins Post by MotoBuddha on 12/17/10 at 10:30:16 De-greased but not de-oxidized. Before http://i280.photobucket.com/albums/kk182/motobuddha/7389b914.jpg After http://i280.photobucket.com/albums/kk182/motobuddha/1631f1fd.jpg |
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Title: Re: The project begins Post by babyhog on 12/17/10 at 10:52:45 Looks like the dishwasher to me..... You must have a very nice wife. ;D |
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Title: Re: The project begins Post by justin_o_guy2 on 12/17/10 at 11:19:35 Theres a chance shes not home,,, |
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Title: Re: The project begins Post by MotoBuddha on 12/17/10 at 11:50:17 No wife. |
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Title: Re: The project begins Post by MotoBuddha on 12/17/10 at 12:07:02 Granite countertops are good for more than looking cool and increasing home values. They're probably the flattest thing in the house and therefore good for checking whether a rotor is true. After scraping crud from the center, put the rotor in several places, turn it to several positions, check for wobble. http://i280.photobucket.com/albums/kk182/motobuddha/70fe4f2e.jpg It felt and sounded a little warped when I rolled the bike off the truck and into the garage. Shoof... shoof... shoof... Sure enough. If the rotor had been true, the sound could mean the wheel isn't true. Of course, that still might be the case. |
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Title: Re: The project begins Post by MotoBuddha on 12/18/10 at 13:34:23 Adventures in welding land today. My first time with a welder, thanks to my buddy at the custom bike shop. Someone with experience and skill could have filled the holes without making more along the way. ::) Gotta learn somehow. http://i280.photobucket.com/albums/kk182/motobuddha/59f69fbf.jpg I still have a lot of smoothing to do. Then it's off to blasting and powdercoat. |
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Title: Re: The project begins Post by SavRon on 12/18/10 at 14:35:18 Man ,you have a serious project in the works. Its gonna be a totally new bike when finished. Can't wait to see it completed. ...and, I commend you on your workshop,,,granite worktops, dishwasher/degreaser, and NO wife to interfere with the cash flow...Kudos to you Bro. :) |
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Title: Re: The project begins Post by justin_o_guy2 on 12/18/10 at 20:12:54 If youre trying to jump a gap, you can lay a light piece in the gap & use that. Also, joining from gusset to frame tube, recommend focusing on the gusset & build to the frame tubing, dont want the tube to suffer too much. |
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Title: Re: The project begins Post by MotoBuddha on 12/19/10 at 08:24:42 Well, there's always something to interrupt you in the middle of working on something. This time it was not having a 1/2" to 3/8" adapter for the torque wrench. I have a 3/8" to 1/2" converter, but that's not what I needed. So I figured I'd remove the cam chain tensioner so I could send it off to Verslagen for modding. Many were the times I've managed to get a C-clip off with some kind of pointed object, but it wasn't working this time. I'd need the proper tool, which I also didn't have. So off to the closest seller of sockets, pliers and such, AutoZone. Adapter? Yes. C-clip pliers? No. But I got a bucket of carb soak while I was at it. Then off to Lowe's to see if they had C-clip pliers. Yes, but only one choice -- some pricey Vise Grip ones in a pack with 90º, 45º and straight tips. Sheesh, whatever. |
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Title: Re: The project begins Post by MotoBuddha on 12/19/10 at 09:39:59 Yum. The joys of a bike that has been sitting a couple of years. At least the seller claimed it was only two years. Does anyone ever confess to longer? http://i280.photobucket.com/albums/kk182/motobuddha/8a893bb4.jpg http://i280.photobucket.com/albums/kk182/motobuddha/18558a5b.jpg |
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Title: Re: The project begins Post by Edgar on 12/19/10 at 11:42:41 My goodness!!! That's far worse than my carb which was allegedly sitting for 3years!!! Why's it green? |
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Title: Re: The project begins Post by verslagen1 on 12/19/10 at 11:49:37 WATER |
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Title: Re: The project begins Post by MotoBuddha on 12/19/10 at 11:58:01 "Well, you know, it's been sittin' a couple of years (underwater)." ;D |
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Title: Re: The project begins Post by justin_o_guy2 on 12/19/10 at 14:27:55 53405756494442404B14250 wrote:
Okay, Ill give ya that,, but is it from moisture absorbed by the alcohol in the gas? |
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Title: Re: The project begins Post by verslagen1 on 12/19/10 at 14:45:09 5F4046415C5B6A5A6A52404C07350 wrote:
Okay, Ill give ya that,, but is it from moisture absorbed by the alcohol in the gas? [/quote] So you're thinking the petcock failed and all the gas in the tank e vapor ated out of the bowl? |
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Title: Re: The project begins Post by justin_o_guy2 on 12/19/10 at 18:24:22 Well, no, hadnt thot of that,, just wondering what youre thinking is. I looked at it, saw it was funky, & didnt even think "water" till you said it.. I sure cant say thats not right,, I know Ive never seen the inside of a carb that color, so, Im goin with ya on Water bing involved, Im just asking whaere you think it might have come from.. You suppose its from water absorbed by the gas in the bowl? Or is humidity enough to do that? |
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Title: Re: The project begins Post by MotoBuddha on 12/19/10 at 19:07:09 I soaked the bowl and some other parts for a few hours and they look fine now. So I dropped the whole carb in the soup for an overnight soak. |
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Title: Re: The project begins Post by justin_o_guy2 on 12/19/10 at 23:29:02 Right after you removed all the rubber parts, right? |
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Title: Re: The project begins Post by MotoBuddha on 12/20/10 at 06:18:40 Now it looks less like something the swamp creature dragged in. http://i280.photobucket.com/albums/kk182/motobuddha/852fca86.jpg |
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Title: Re: The project begins Post by ralfyguy on 12/20/10 at 09:24:43 Dang, like new! What did you soak it in? |
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Title: Re: The project begins Post by MotoBuddha on 12/20/10 at 09:46:17 http://berrymanproducts.com/Default.aspx?tabid=146 http://i280.photobucket.com/albums/kk182/motobuddha/8cc30734.jpg Got it at AutoZone. |
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Title: Re: The project begins Post by justin_o_guy2 on 12/20/10 at 10:06:16 293A2D2C333E383A316E5F0 wrote:
Okay, Ill give ya that,, but is it from moisture absorbed by the alcohol in the gas? [/quote] So you're thinking the petcock failed and all the gas in the tank e vapor ated out of the bowl?[/quote] & I replied Well, no, hadnt thot of that,, just wondering what youre thinking is. I looked at it, saw it was funky, & didnt even think "water" till you said it.. I sure cant say thats not right,, I know Ive never seen the inside of a carb that color, so, Im goin with ya on Water bing involved, Im just asking whaere you think it might have come from.. You suppose its from water absorbed by the gas in the bowl? Or is humidity enough to do that? |
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Title: Re: The project begins Post by MotoBuddha on 12/27/10 at 17:18:24 What can one do on a snowy Christmas weekend? Get the carb looking all factory fresh. All new jets on the way. With the shape this pig was in, I don't trust the existing jets. http://i280.photobucket.com/albums/kk182/motobuddha/85a4891e.jpg Now I just need to figure out how to get the #@/x*¿ float pin out. I've pushed. I've tried heat. I've tried WD40. I tried swearing. Nothing. |
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Title: Re: The project begins Post by Edgar on 12/27/10 at 21:38:02 Mine wasnt sticking out either, so What I did is find a small diameter nail, cut off the pointy end with my grinder and tapped the nail against the pivot pin on the opposite of the flat head side ever so lightly, and eventually it stuck out enough to where I pulled it out with wire cutters. Really smooth and no damage at all to the pivot pin |
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Title: Re: The project begins Post by verslagen1 on 12/27/10 at 23:06:43 Becareful with that. I've seen someone break one of the supports off. Apply some penetrating oil. then I'd bridge the 2 with a clamp. Then punch it out. |
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Title: Re: The project begins Post by MotoBuddha on 12/28/10 at 11:05:05 New rotor arrived. Ooooo, holes! http://i280.photobucket.com/albums/kk182/motobuddha/ea04b596.jpg And I used my very primitive welding "skills" to make a tool for disassembling the forks. http://i280.photobucket.com/albums/kk182/motobuddha/035558f4.jpg |
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Title: Re: The project begins Post by verslagen1 on 12/28/10 at 11:24:26 Is that an EBC rotor? And hey, primitive is all right, you gotta learn somehow. |
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Title: Re: The project begins Post by MotoBuddha on 12/28/10 at 11:54:17 Yeah, EBC, via CheapCycleParts.com. All I could find anywhere was that or stock. |
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Title: Re: The project begins Post by MotoBuddha on 12/28/10 at 14:08:43 After trying all the sensible methods of removing the float pin, I had to resort to senseless force. I had already ordered a new pin and floats in case it came to this. I used the Dremel to cut a section out of middle of the pin, and the float along with it. The headless part of the pin pretty much dropped right out, but I had to take pliers to the piece with the head and wrestle it out. Carefully. Sheesh. http://i280.photobucket.com/albums/kk182/motobuddha/7999a4ee.jpg |
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Title: Re: The project begins Post by ralfyguy on 12/28/10 at 18:14:33 I LOVE these threads! :) |
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Title: Re: The project begins Post by Bobbert on 12/29/10 at 18:03:05 This is great! Not a lot of people take these things apart to clean and actually document it. I'm glad you're doing all of this the right way. It's inspiring me to avoid my Kuldgey habits |
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Title: Re: The project begins Post by Boule’tard on 12/29/10 at 19:07:43 Yeah this is an interesting thread! Very "snuggly" to see this kind of wintertime restoration. It looks like you are doing a very thorough job. Are you pulling the forks apart just to inspect the bushings, or gonna put in cartridge emulators ;) |
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Title: Re: The project begins Post by MotoBuddha on 12/29/10 at 19:30:45 I'm shortening the forks and replacing bushing, seals, etc. while I'm at it. My garage is kind of cold, so the forks have been sitting all day upside down in a drain pan. Drip... drip... drip... |
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Title: Re: The project begins Post by MotoBuddha on 12/30/10 at 15:28:38 Went to the powercoater this afternoon to look at color samples for the frame. I'm leaning toward a dark-ish gold. That surprises me because I'm not a gold kind of guy. Or maybe a dark red. Or charcoal. Just not black. |
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Title: Re: The project begins Post by MotoBuddha on 12/31/10 at 11:38:02 I cobbled together an engine stand today. http://i280.photobucket.com/albums/kk182/motobuddha/a56efb6f.jpg When I removed the starter, the area beneath it was filled with mud, leaves and who knows what else. Cleaning cleaning cleaning... |
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Title: Re: The project begins Post by justin_o_guy2 on 12/31/10 at 13:19:08 Ive been wondering where my erector set went. |
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Title: Re: The project begins Post by MotoBuddha on 01/01/11 at 10:04:39 Disassembled the forks following the instructions here: http://www.chopcult.com/forum/showthread.php?t=7129 http://i280.photobucket.com/albums/kk182/motobuddha/7cb64509.jpg I also removed the clearcoat from the fork bottoms in preparation for polishing. I thought I'd try Rust-Oleum Clearcoat & Base Coat Remover instead of aircraft stripper. It worked very quickly and easily and was way less noxious than aircraft stripper. The engine side covers are next. |
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Title: Re: The project begins Post by MotoBuddha on 01/01/11 at 12:32:29 Here are shots of stripping the clearcoat on the clutch cover. Spray on and wait until it looks like this: http://i280.photobucket.com/albums/kk182/motobuddha/f37350d2.jpg Wipe it off, repeat as necessary. http://i280.photobucket.com/albums/kk182/motobuddha/a469499e.jpg You end up with nice scabby stuff like this: http://i280.photobucket.com/albums/kk182/motobuddha/6f11bc78.jpg |
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Title: Re: The project begins Post by justin_o_guy2 on 01/01/11 at 15:32:19 Looks like a few days after a good sunburn. |
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Title: Re: The project begins Post by ralfyguy on 01/01/11 at 15:47:44 I totally enjoy this education I'm getting following this thread. :) |
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Title: Re: The project begins Post by MotoBuddha on 01/01/11 at 15:58:01 Oh, a tip about removing the snap rings that retain the fork seals. It can be hard to tell where the open ends of the rings are since they're buried in grooves. In my case, there was rust buildup at the open ends. Ah, there you are. |
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Title: Re: The project begins Post by Boule’tard on 01/01/11 at 16:58:05 That's awesome MotoBuddha, I didn't know that stuff could come off so easy. Do you anticipate much work to keep it shiny? |
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Title: Re: The project begins Post by MotoBuddha on 01/01/11 at 17:26:51 It will be re-clearcoated. Oh, and while the clearcoat on the engine covers bubbled, the coating on the fork legs more or less turned to powder. I guess they use different stuff on the forks because they get a lot of blasting from road grit. |
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Title: Re: The project begins Post by MotoBuddha on 01/01/11 at 17:33:08 I discovered these surface irregularities on the clutch cover. I wonder if the crackling is from exhaust heat. Suzuki protects your ankle from the heat, but not the cover. http://i280.photobucket.com/albums/kk182/motobuddha/4f27d489.jpg http://i280.photobucket.com/albums/kk182/motobuddha/f9d8b1d4.jpg |
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Title: Re: The project begins Post by ralfyguy on 01/01/11 at 21:13:29 No it's the casting. Just simply didn't get polished out good enough. You can see it on the inside too. At least on mine it's like that. That exhaust doesn't nearly get hot enough to do that to the aluminum. |
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Title: Re: The project begins Post by MotoBuddha on 01/02/11 at 04:53:06 That's good to know. Looks like more sanding in my future than I'd planned on. |
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Title: Re: The project begins Post by fsmidt on 01/02/11 at 13:12:00 thanks for the link,nice website http://www.chopcult.com/forum/showthread.php?t=7129 |
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Title: Re: The project begins Post by MotoBuddha on 01/02/11 at 13:18:14 70657B7F7262160 wrote:
I got the link from elsewhere here a SuzukiSavage.com http://suzukisavage.com/cgi-bin/YaBB.pl?num=1289315334 |
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Title: Re: The project begins Post by MotoBuddha on 01/02/11 at 15:19:29 I started sanding the fork bottoms in preparation for polishing. The factory brushed finish is deeper than I expected. About an hour with 220 grit looks like the one on the left. Finer grits to follow. http://i280.photobucket.com/albums/kk182/motobuddha/00621104.jpg http://i280.photobucket.com/albums/kk182/motobuddha/4d3816f7.jpg |
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Title: Re: The project begins Post by ralfyguy on 01/02/11 at 16:29:18 You gonna high gloss polish all the clear coated parts? Are you gonna clear coat them again? I polished my clutch cover, but didn't clear coat it, because didn't know what to use and am not much of a painter anyways. I have to repolish frequently and keep water drops off of it, because it stains rather quickly. |
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Title: Re: The project begins Post by MotoBuddha on 01/02/11 at 17:18:42 Yes, I'm going to clearcoat them again. I'm polishing to get rid of various scratches. Of course, they could get scratched again, but it's something I want to do. Who knows, maybe once the pieces are polished I'll decide to have them nickel plated instead. Oh, and I'm going to polish the valve adjustment covers too. |
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Title: Re: The project begins Post by buttgoat1 on 01/03/11 at 09:28:34 DuplicoLor make a black chrome paint, a 2 step spray can process for chrome and bright aluminum. thats my plan for the rims and forks. |
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Title: Re: The project begins Post by MotoBuddha on 01/03/11 at 13:05:44 Und now ve danse! http://i280.photobucket.com/albums/kk182/motobuddha/9a24022f.jpg |
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Title: Re: The project begins Post by MotoBuddha on 01/06/11 at 06:37:08 A marvelous extravagance just arrived from England: bar-end turn signals by Oberon. Beautifully machined aluminum bodies. http://i280.photobucket.com/albums/kk182/motobuddha/cf4edc1b.jpg Here's what they look like installed (on a different bike). They're two sided, so they're visible from the front and back. I hope they make separate rear signals unnecessary. There's a state inspection station nearby that's also a custom bike shop. They'll be able to tell me if I'd pass inspection. http://i280.photobucket.com/albums/kk182/motobuddha/6593a151.gif They wouldn't really work with buckhorn bars, but I'll be going with clip-ons, which also makes installation really easy. I won't need to drill the bars for wiring, just the plastic caps. http://i280.photobucket.com/albums/kk182/motobuddha/3563dc6a.jpg |
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Title: Re: The project begins Post by verslagen1 on 01/06/11 at 07:23:39 Only trouble you might have is they're supposed to be red when facing rear. |
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Title: Re: The project begins Post by MotoBuddha on 01/06/11 at 07:38:03 Not for blinkers. |
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Title: Re: The project begins Post by kernel ken on 01/06/11 at 08:15:33 OK-just couldn't stand it anymore...after seeing those COOL turn signals I had to tell you this is a fantastic post. You've given me some good tips for my project bike. BTW, are you building up one of the Ryca CS-1 Cafe racers? The picture of the clip-ons is the same one they use. At present, I'm 42nd on their kit ship list. |
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Title: Re: The project begins Post by MotoBuddha on 01/06/11 at 08:36:19 Yes, it's going to be a RYCA -- more or less. I haven't asked where I am on their list. |
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Title: Re: The project begins Post by MotoBuddha on 01/07/11 at 11:50:31 The mailman brought a present. Fork seals (wipers, bushings, etc.) and carb parts. http://i280.photobucket.com/albums/kk182/motobuddha/2e0cf10a.jpg http://i280.photobucket.com/albums/kk182/motobuddha/8e0548d6.jpg Too bad I'll be tied up this weekend with other work. :-X |
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Title: Re: The project begins Post by Edgar on 01/07/11 at 12:21:23 Can't wait to see those clip ons installed! |
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Title: Re: The project begins Post by MotoBuddha on 01/07/11 at 12:45:34 Many steps before that happens. |
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Title: Re: The project begins Post by RidgeRunner13 on 01/07/11 at 12:58:47 Are those clip-ons for 1" controls? |
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Title: Re: The project begins Post by MotoBuddha on 01/07/11 at 13:18:50 Yes. Ryca is having them made up so the 1" LS650 controls and switch pods bolt right on. |
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Title: Re: The project begins Post by MotoBuddha on 01/08/11 at 07:31:43 Mr. Fussy strikes again. The float bowl had rough casting marks and a few dings, so break out the sanding paper and Dremel. Now I need to decide if I want to leave it with a brushed finish or continue on to polishing. Before: http://i280.photobucket.com/albums/kk182/motobuddha/8b9bd580.jpg After: http://i280.photobucket.com/albums/kk182/motobuddha/907e97c6.jpg |
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Title: Re: The project begins Post by ralfyguy on 01/08/11 at 10:48:59 Well it's definitely gonna get dull again on it's own. |
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Title: Re: The project begins Post by MotoBuddha on 01/08/11 at 11:22:21 Clear powdercoat. |
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Title: Re: The project begins Post by MotoBuddha on 01/08/11 at 12:06:12 Temporary primer on the frame to check the smoothness of my welding/grinding/filling/sanding before having it blasted and powdercoated. http://i280.photobucket.com/albums/kk182/motobuddha/1b099413.jpg |
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Title: Re: The project begins Post by MotoBuddha on 01/08/11 at 12:22:45 It's not a lot of fun sanding around the brake and fender lugs. More work to come. http://i280.photobucket.com/albums/kk182/motobuddha/9421dcbb.jpg http://i280.photobucket.com/albums/kk182/motobuddha/1282be4f.jpg |
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Title: Re: The project begins Post by MotoBuddha on 01/08/11 at 17:36:48 There we go, all cleaned, rebuilt and assembled. For now, until it's time to fiddle with the jetting. http://i280.photobucket.com/albums/kk182/motobuddha/102013b6.jpg |
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Title: Re: The project begins Post by verslagen1 on 01/08/11 at 18:00:34 put something on that cap or it'll rust. |
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Title: Re: The project begins Post by MotoBuddha on 01/08/11 at 18:39:04 It came with a nice protective layer of grime. I'm thinkin' crinkle powdercoat, or maybe the same color as the frame is going to be. |
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Title: Re: The project begins Post by psi357 on 01/09/11 at 07:43:11 I actually registered to this forum to say your doing a heck of a job there! Someone on a forum I frequent was debating buying a Savage so I stopped by to see what you guys had to say about them. Been checking on this thread every day since. Great work. Oh, and he bought it ;D |
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Title: Re: The project begins Post by MotoBuddha on 01/09/11 at 08:46:07 The tank is in exile until it's extradited to Ryca where it will be tortured into shape. http://i280.photobucket.com/albums/kk182/motobuddha/2df30d96.jpg (I really need to do some raking.) |
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Title: Re: The project begins Post by MotoBuddha on 01/14/11 at 17:15:19 I have a guy in Ohio making this for me. http://i280.photobucket.com/albums/kk182/motobuddha/6d1a6fa8.jpg I know, I know... proper filtration and all that, but it's just for photos and such. Otherwise it can serve as a helmet for my pointy little head. |
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Title: Re: The project begins Post by MotoBuddha on 01/15/11 at 10:45:23 Got the fork bottoms sanded down to 1000 grit. At that point the back of the sandpaper is about as rough as the front. They still need the rouge and buffing wheel treatment, but just to see how things might look, I spent a minute or two using some aluminum polish by hand. (The lower fork bottom is polished, the upper one 1000 grit.) http://i280.photobucket.com/albums/kk182/motobuddha/29510967.jpg http://i280.photobucket.com/albums/kk182/motobuddha/2e35ce14.jpg |
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Title: Re: The project begins Post by MotoBuddha on 01/15/11 at 10:51:46 In the middle of polishing the fork bottoms, I got wondering whether the fork tubes are actually straight. Since everything is disassembled, it was easy to do a little test a friend told me about. I placed them on a table and rolled them back and forth while snugged up to each other. If either or both of them weren't straight, they wouldn't roll very well and a gap would appear between them. They passed. |
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Title: Re: The project begins Post by MotoBuddha on 01/15/11 at 11:38:26 After all the tedious hand work of sanding the fork bottoms, it's nice to employ the brutal efficiency of power tools. With the Ryca kit, you send them your rear hub and they lace it up to an 18" rim and, if you want, mount and balance a tire. So I got out the angle grinder and in a minute or so, presto, the hub was free. http://i280.photobucket.com/albums/kk182/motobuddha/17830f99.jpg |
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Title: Re: The project begins Post by justin_o_guy2 on 01/15/11 at 12:27:06 103229321F283939353C5D0 wrote:
doesnt sound like this guy has spent much time hunting a decent cue stick. Glad ya know the way to do that now, & Thanks for the updates, Im havin a vicarious blast. |
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Title: Re: The project begins Post by verslagen1 on 01/15/11 at 12:51:50 05273C270A3D2C2C2029480 wrote:
The PO probably used Klotz fork oil. 8-) |
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Title: Re: The project begins Post by MotoBuddha on 01/15/11 at 13:47:30 Take a bit of 1/8" steel bar, grind the end a bit and -- shazam -- a tool to remove the valve timing inspection cover. It ain't no Honda part #07700-0010001, but it works. Just turn it with a crescent wrench. http://i280.photobucket.com/albums/kk182/motobuddha/b6c9dcec.jpg |
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Title: Re: The project begins Post by MotoBuddha on 01/15/11 at 13:50:12 Klotz? I think it was more a matter of the PO being a klutz. |
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Title: Re: The project begins Post by ralfyguy on 01/15/11 at 16:22:45 What aluminum polish did you use? |
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Title: Re: The project begins Post by MotoBuddha on 01/15/11 at 16:32:45 Mother's. It's what I happened to have around. |
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Title: Re: The project begins Post by Boule’tard on 01/15/11 at 16:40:34 1E3C273C112637373B32530 wrote:
I had almost the same idea :D http://i54.tinypic.com/2s846y8.jpg Great going on this build!! I don't think anyone has so thoroughly redone their bike since Truckinduc. |
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Title: Re: The project begins Post by Edgar on 01/15/11 at 22:30:17 Earlytimez did quite a rebuild as well |
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Title: Re: The project begins Post by BurnPgh on 01/15/11 at 22:34:19 57756E75586F7E7E727B1A0 wrote:
Once you get it off, just go ahead and get one from an intruder 800/s50. Takes a 10mm hex and fits perfectly. I will never again curse and grind up the timing inspection cover trying to cautiously remove it as if i were defusing a ticking bomb. |
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Title: Re: The project begins Post by justin_o_guy2 on 01/15/11 at 22:56:34 I will never again curse and grind up the timing inspection cover trying to cautiously remove it as if i were defusing a ticking bomb. Ive been so afraid of that blasted thing. I Want, man, I REAlly, really want to tighten the thing more when Im putting it together, but I dont, & it doesnt fall out, & it comes out when I need it to. & It has antisieze in it, too. |
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Title: Re: The project begins Post by MotoBuddha on 01/16/11 at 06:59:48 "...get one from an intruder 800/s50. Takes a 10mm hex and fits perfectly." Thanks for the cool tip. |
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Title: Re: The project begins Post by kimchris1 on 01/16/11 at 07:09:35 Motobuddha, Wow what an interesting read this is. I look forward to each time you post a new progress you have made. This is going to be a very nice bike once it is completed. Continued success and keep the posts and pics coming.. Hugs.. kim :) |
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Title: Re: The project begins Post by MotoBuddha on 01/16/11 at 11:16:47 Starting to work on some of the ugly welds. http://i280.photobucket.com/albums/kk182/motobuddha/fb61bb03.jpg Go Bears. |
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Title: Re: The project begins Post by MotoBuddha on 01/17/11 at 13:05:25 Earlier I posted about how the bottom of my clutch cover looked like dry, cracked earth. http://i280.photobucket.com/albums/kk182/motobuddha/028ecbae.jpg http://i280.photobucket.com/albums/kk182/motobuddha/dd491fe6.jpg After about 15 minutes with 220 grit sandpaper it was surprisingly smooth. There are still some pits that will need more work, but it has been much easier so far than I expected. http://i280.photobucket.com/albums/kk182/motobuddha/dd5a13a6.jpg Here's another example. The edge used to look like the first one, but now it looks like the second one. http://i280.photobucket.com/albums/kk182/motobuddha/a7d3df68.jpg http://i280.photobucket.com/albums/kk182/motobuddha/f5a5db24.jpg |
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Title: Re: The project begins Post by verslagen1 on 01/17/11 at 14:23:41 Becareful with die cast parts. Pores normally hide under the surface. If you sand to remove them, you might reach the other side before you get rid of them all. |
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Title: Re: The project begins Post by MotoBuddha on 01/17/11 at 14:33:07 Since most of the ugliness was in areas that will be hidden by the exhaust, I'm not going to get anal about removing every divot. Things just need to pass the 10-foot test in case I decide to go with a high pipe some day. ;) |
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Title: Re: The project begins Post by babyhog on 01/17/11 at 16:22:45 I DESPISE sanding, so more power to ya! Looking good. |
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Title: Re: The project begins Post by crackmonkey on 01/17/11 at 17:03:43 great attn. to detail. looks sweet. cant wait until you get your ryca parts |
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Title: Re: The project begins Post by MotoBuddha on 01/18/11 at 12:15:16 A little something today from the UPS guy. http://i280.photobucket.com/albums/kk182/motobuddha/e9aefb66.jpg A "previously owned" cylinder should arrive later this week, then they'll both go out for boring. Why am I not just sending out the cylinder I already have? It's one of my odd habits, inspired by the First Rule of Wing Walking: don't let go of what you have until you have hold of something else. And maybe the troublesome thread for the 103mm head bolt will be in better shape. |
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Title: Re: The project begins Post by justin_o_guy2 on 01/18/11 at 12:35:09 Theres a product that can be put in the cylinder that increases life. Ask some of the hot rodders. |
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Title: Re: The project begins Post by MotoBuddha on 01/18/11 at 12:40:47 Then, moments later, the mailman delivered this. http://i280.photobucket.com/albums/kk182/motobuddha/7176e873.jpg |
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Title: Re: The project begins Post by greenmonster on 01/18/11 at 13:20:11 I've gotta get a mail man like yours! |
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Title: Re: The project begins Post by MotoBuddha on 01/18/11 at 13:32:37 It's Two-fer Tuesday, I guess. |
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Title: Re: The project begins Post by verslagen1 on 01/18/11 at 13:46:35 Yes it is... thanks for reminding me... no cooking tonight kids! ;D ;D |
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Title: Re: The project begins Post by MotoBuddha on 01/19/11 at 12:28:10 Mail's in. http://i280.photobucket.com/albums/kk182/motobuddha/c56d14f0.jpg Except for the usual external grime, everything looks good. Thanks Tom. |
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Title: Re: The project begins Post by greenmonster on 01/19/11 at 13:15:13 That's funny, I have one of those in my living room. They make a heck of a rug ornament. |
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Title: Re: The project begins Post by MotoBuddha on 01/19/11 at 18:18:05 Looks like the threads for that troublesome 103mm head bolt are in decent shape. Awright! http://i280.photobucket.com/albums/kk182/motobuddha/09ac3f70.jpg |
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Title: Re: The project begins Post by Bubba on 01/20/11 at 06:30:16 Moto, that would be the 130mm bolt...been there done that! |
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Title: Re: The project begins Post by MotoBuddha on 01/20/11 at 06:42:08 Number dyslexia. |
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Title: Re: The project begins Post by MotoBuddha on 01/22/11 at 13:23:26 More sanding. Down to 2000 grit on some pieces. Down to the nubs on my fingers. http://i280.photobucket.com/albums/kk182/motobuddha/23d002a7.jpg Found some gouges on the bottom side of the covers -- evidence the PO must have had a little excursion off the pavement. I'm staring at the rear hub, brake and cush drive, hoping the polishing elves will take care of all it while I sleep. |
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Title: Re: The project begins Post by Boule’tard on 01/22/11 at 14:30:53 Man, what a great thread! See what Ryca says about your gas tank; if it needs a thicker cap gasket I'll make one and donate it to the project. ;) |
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Title: Re: The project begins Post by MotoBuddha on 01/22/11 at 15:22:49 I'm thinking of going with a flush mount gas cap. My bike painter buddy has lots of experience installing them. |
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Title: Re: The project begins Post by verslagen1 on 01/22/11 at 15:50:08 be sure to document how, been looking at them too. |
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Title: Re: The project begins Post by MotoBuddha on 01/24/11 at 12:01:56 The cylinder is off to be bored, blasted and painted. http://i280.photobucket.com/albums/kk182/motobuddha/5357eb03.jpg |
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Title: Re: The project begins Post by MotoBuddha on 01/24/11 at 15:56:38 The engine is out of the frame, so I needed to figure a different way to remove the countershaft pulley. The usual methods were out of the picture since the belt was long gone. I had cut it off with the angle grinder and thrown it in the trash because it kept getting in the way as I tried to remove the rear wheel. Also, the left case is off the engine, getting ready to polish, and I wasn't in the mood to put it back on just for this. So I fiddled with things a bit, looked through my tools, tried a couple of things, then had an idea. A shock absorber preload adjusting wrench is good for grabbing a cylinder. The pulley is just bigger. I could wedge it against the crankcase and... http://i280.photobucket.com/albums/kk182/motobuddha/43f2db2e.jpg http://i280.photobucket.com/albums/kk182/motobuddha/98cee5c4.jpg http://i280.photobucket.com/albums/kk182/motobuddha/6caf058c.jpg There we go. :) |
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Title: Re: The project begins Post by justin_o_guy2 on 01/24/11 at 16:26:50 So, you got it? |
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Title: Re: The project begins Post by MotoBuddha on 01/24/11 at 16:30:11 Yeah, came off easily. |
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Title: Re: The project begins Post by gerald.hughes on 01/24/11 at 16:35:52 Why not just wrap some leather around it and throw a large plumber's wrench on it? |
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Title: Re: The project begins Post by MotoBuddha on 01/24/11 at 16:40:13 Because I don't have a plumber's wrench. And the only leather straps I have are belts I don't want to mess up. Though I could skip the leather since I'm not reusing the pulley. Besides, I think my solution is more elegant -- the simple repurposing of an actual tool. Slip it into place, and bingo. |
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Title: Re: The project begins Post by crackmonkey on 01/24/11 at 17:55:17 nice tool re-purpose! so you are doing a chain conversion aswell? |
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Title: Re: The project begins Post by justin_o_guy2 on 01/24/11 at 18:49:56 I love winning against a problem like that/. Wanna come unclog this drain now, smartypants? |
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Title: Re: The project begins Post by MotoBuddha on 01/25/11 at 07:37:17 4A5B484A42444647424C50290 wrote:
http://i280.photobucket.com/albums/kk182/motobuddha/a3720756.jpg |
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Title: Re: The project begins Post by Boule’tard on 01/25/11 at 09:03:02 You could probably win the current scavenger hunt (over in the cafe, challenge proposed by youzguyz) just by taking a photo of this project. Winter project with the highest number of detached parts wins. |
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Title: Re: The project begins Post by MotoBuddha on 01/25/11 at 11:35:59 Would I show the naked frame or the trash barrel full of parts? ;D |
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Title: Re: The project begins Post by youzguyz on 01/25/11 at 12:44:50 0C2E352E033425252920410 wrote:
Saw the pretty pictures. Wanna see the barrel too!! :P |
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Title: Re: The project begins Post by crackmonkey on 01/25/11 at 13:23:46 very cool... since you did that you probably could have used some other wheel and converted to disk brakes as well |
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Title: Re: The project begins Post by MotoBuddha on 01/25/11 at 14:08:15 2A3C262934262A29530 wrote:
Saw the pretty pictures. Wanna see the barrel too!! :P[/quote] http://i280.photobucket.com/albums/kk182/motobuddha/b646aea0.jpg |
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Title: Re: The project begins Post by verslagen1 on 01/25/11 at 14:17:11 Hope you're throwing that away, I see a couple of things some will want. |
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Title: Re: The project begins Post by MotoBuddha on 01/25/11 at 14:18:00 28392A2820262425202E324B0 wrote:
Maybe phase two. But there's a lot to be said for the simplicity of a drum brake on the rear. What I'm itching to do for phase two is fix the way the left side of the swingarm arcs out to clear the belt and pulley that aren't there anymore. Seems like I could get a second swing arm, cut both in half, weld the two right sides together, then cut the axle end & shock mount off the new left side and weld on the axle end from the old left side. Then shorten the upper shock mount to match. |
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Title: Re: The project begins Post by MotoBuddha on 01/25/11 at 14:18:30 2B382F2E313C3A38336C5D0 wrote:
There will be a sale. |
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Title: Re: The project begins Post by MotoBuddha on 01/25/11 at 20:15:48 The tool solution in reply #145 above got me thinking about how to tighten and loosen the new sprocket without the engine together, or just more elegantly than the usual chain-wheel-brake-2x4 method. The sprocket has three holes. I don't know what their purpose is, but I can make use of them. http://i280.photobucket.com/albums/kk182/motobuddha/a3720756.jpg So I designed an easy-to-make tool. A piece if steel bar, drilled for a couple of bolts. One bolt fits in the larger hole (deeper than shown here) and the other rests against the outer edge of the sprocket or on top of the chain if it's in place. The question is whether there's clearance to get at the nut. Gotta go measure. Maybe the tool attaches to the back of the sprocket. http://i280.photobucket.com/albums/kk182/motobuddha/545d6337.jpg It would give me the leverage I need to keep the sprocket from spinning. I think the same basic idea would work on the pulley. One bolt goes inside the lip, the other outside, against the belt. Or turn around the bolt further from the end so the head sticks out and engages between the pulley teeth to keep the pulley from spinning between the bolts. |
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Title: Re: The project begins Post by justin_o_guy2 on 01/25/11 at 21:23:55 Why not leave it off till its easy to put on? |
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Title: Re: The project begins Post by james may on 01/25/11 at 21:26:27 That's cool looking graphic did you use a CAD program to design it or some kind of paint? It's got a more cartoony and vivid look that most of the CAD program full skins i've used. But it's deffinately 3d like. |
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Title: Re: The project begins Post by MotoBuddha on 01/26/11 at 04:57:45 5B5A414A5D5B565F4A2F0 wrote:
I did it with Illustrator. |
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Title: Re: The project begins Post by crackmonkey on 01/26/11 at 05:01:27 vw guys have a similar tool for removing the rear axel nuts. it bolts into 2 of the lug holes. they work really well. for clearance there is an arc cut out of the bar that goes around the area of the axel nut |
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Title: Re: The project begins Post by MotoBuddha on 01/29/11 at 10:46:30 Now it's time to clean up this pig. http://i280.photobucket.com/albums/kk182/motobuddha/a21d8bf9.jpg More examples of rough casting and bits that weren't machined at the factory. http://i280.photobucket.com/albums/kk182/motobuddha/9cf178d6.jpg http://i280.photobucket.com/albums/kk182/motobuddha/df6f17f8.jpg I think I'll end up painting the center section and polishing only the outer parts. Here's a shot of one side pretty much raw and then the other side with a little sanding and a bit of hand-applied polish to see how it's coming along. http://i280.photobucket.com/albums/kk182/motobuddha/8c3dfdba.jpghttp://i280.photobucket.com/albums/kk182/motobuddha/51fdc970.jpg If I were a machinist, I'd mill a lot of mass off the hub. Hell, If I could just mount it on a lathe to make the sanding easier. :-/ |
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Title: Re: The project begins Post by MotoBuddha on 01/29/11 at 11:20:31 And then there's the front hub. http://i280.photobucket.com/albums/kk182/motobuddha/4833d149.jpg Close-ups show all the roughness I need to work on. More signs of it being an entry level bike. It'll take some finesse to grind off the casting info thing without leaving a flat spot or gouges. http://i280.photobucket.com/albums/kk182/motobuddha/fd60d07c.jpg http://i280.photobucket.com/albums/kk182/motobuddha/45f4b4ab.jpg The ends will be no fun to do. http://i280.photobucket.com/albums/kk182/motobuddha/8d801f6a.jpg |
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Title: Re: The project begins Post by odmanout on 01/29/11 at 12:36:07 Why not take the hubs to a machine shop and have the casting "roughage" turned off? |
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Title: Re: The project begins Post by MotoBuddha on 01/29/11 at 13:08:39 Yeah, I'm looking for a machine shop to help me. But the more I do by myself, the more rewarding the end result. |
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Title: Re: The project begins Post by MotoBuddha on 01/29/11 at 13:09:33 Another before and after shot, this time of the valve adjustment covers. http://i280.photobucket.com/albums/kk182/motobuddha/42778eb3.jpg |
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Title: Re: The project begins Post by justin_o_guy2 on 01/29/11 at 13:32:52 I made a strap out of leather & hung it on the front spindle of the only really nice bicycle I had. It kept it polished for me. |
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Title: Re: The project begins Post by MotoBuddha on 01/30/11 at 13:30:29 Well, I put my man pants on and tackled the roughness on the inner part of the rear hub. Here's the before, showing all the flash on the ridges. http://i280.photobucket.com/albums/kk182/motobuddha/2ccc19e4.jpg Here's my lovely thumb doing it's thing with some 220 grit paper. http://i280.photobucket.com/albums/kk182/motobuddha/89d14490.jpg And here's the same spot about 10 minutes later. The black spots are voids. http://i280.photobucket.com/albums/kk182/motobuddha/8ce24729.jpg |
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Title: Re: The project begins Post by crackmonkey on 01/30/11 at 13:34:07 those are man pants i dont want to wear... ha ha ha looking good man |
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Title: Re: The project begins Post by Boule’tard on 01/30/11 at 13:45:55 Ugh. I don't think I'd have enough zen in me to do ONE of those hubs per decade. Sans lathe I might stick the axle back in and rig up something with that erector set (or wood) to hold the axle horizontal. Then get at it shoe-shine style with a strip of plumber's cloth. Or stock up on nitrile gloves ;D |
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Title: Re: The project begins Post by MotoBuddha on 01/31/11 at 04:26:15 All the sanding I'm doing must be good for a pound or so of weight loss on the bike. |
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Title: Re: The project begins Post by bill67 on 01/31/11 at 05:30:42 56494F4855526353635B49450E3C0 wrote:
Jog thats and old trick we did that in the 1950s I know know when that got started. |
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Title: Re: The project begins Post by ralfyguy on 01/31/11 at 10:40:22 Concerning the rear hub: Take your Drill and fasten it on a table or vise. Take a piece of allthread rod that fits through the bearings, if necessary make up the difference with Duct Tape to make it snug enough. Stick one end into the drill. Put a big washer by the chuck. Put the rear hub on and then another washer and a nut and tighten. Let the drill run at a slow comfortable speed, because of the circumference of the hub, the speed on the outside will be fast enough for sanding. Also this way not much noise and overheating of the Drill. Just watch out for your fingers. Maybe wanna use some leather gloves. There seems to be a cast seem in the middle that runs axial, you can take that down with a file prior. You could even get a stick of wood with sandpaper on top to get in the grooves. |
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Title: Re: The project begins Post by MotoBuddha on 02/05/11 at 14:20:09 Front hub time. See photos above for what it looked like before. Casting info? What casting info? http://i280.photobucket.com/albums/kk182/motobuddha/52ddde70.jpg http://i280.photobucket.com/albums/kk182/motobuddha/fa47736d.jpg I need to go back and do some more work on the nooks and crannies of the rotor side |
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Title: Re: The project begins Post by justin_o_guy2 on 02/05/11 at 22:35:38 daang, thats sweet. |
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Title: Re: The project begins Post by MotoBuddha on 02/08/11 at 15:19:54 Rats. The last round of sanding left me with a small blister on the tip of my index finger. It makes typing and mousing kind of a drag. Ah, the things we do for motorcycles. |
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Title: Re: The project begins Post by Boule’tard on 02/08/11 at 16:03:55 Small price to pay for several pieces of jewelry, bro. |
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Title: Re: The project begins Post by MotoBuddha on 02/12/11 at 12:22:12 I making progress stripping the tank. Ryca is offering a small discount if you send them a bare tank to work with instead of one they have to blast. I still have most of the underside to deal with. I'm going to hate yellow by the time I'm done. http://i280.photobucket.com/albums/kk182/motobuddha/1b06f844.jpg There are some dings on top of the tank, in front of the gas opening. I think those were from the windscreen mounting hardware. I think the crease is from an unplanned off-pavement trip, the evidence for which is elsewhere on the bike. http://i280.photobucket.com/albums/kk182/motobuddha/12457141.jpg To refresh your memory, here's what it looked like before: http://i280.photobucket.com/albums/kk182/motobuddha/2df30d96.jpg |
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Title: Re: The project begins Post by ralfyguy on 02/12/11 at 14:44:23 I guess by the time you're done, you gonna hate sanding too! ;D |
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Title: Re: The project begins Post by MotoBuddha on 02/13/11 at 08:34:03 Speaking of sanding: http://i280.photobucket.com/albums/kk182/motobuddha/1ab9ede6.jpg No machine buffing yet, but I'm starting to think I like the vintage-looking high lustre better than super smooth chrome-like high polish. Here it is with the sprocket in position. http://i280.photobucket.com/albums/kk182/motobuddha/1b0e131c.jpg |
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Title: Re: The project begins Post by sbaugz on 02/13/11 at 09:02:24 Looking real nice. How many hours do you have into this bike sanding so far? Can't wait to see how this is going to turn out. It'll be interesting to see the difference between your and the one I am making since I am going the complete opposite route- everything is getting dulled down or black powdercoat. |
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Title: Re: The project begins Post by MotoBuddha on 02/13/11 at 09:23:10 Well, the cylinder will be black. ;D |
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Title: Re: The project begins Post by justin_o_guy2 on 02/13/11 at 09:42:26 How are you gonna protect the finish youve worked so hard to create? |
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Title: Re: The project begins Post by JohnBoy on 02/13/11 at 09:43:36 1C3E253E132435353930510 wrote:
I don't care much for the high polish glare of chrome. I feel that done to extreme, it makes things look cheap, like a Japanese toaster. Here in AZ it can be down right dangerous. The sun light off your headlight or even mirrors can prevent you from seeing that truck signaling for a turn. |
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Title: Re: The project begins Post by MotoBuddha on 02/13/11 at 11:22:06 687771766B6C5D6D5D65777B30020 wrote:
Clear paint. |
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Title: Re: The project begins Post by MotoBuddha on 02/13/11 at 11:34:31 Well, a break from the cosmetic stuff and back to the mechanical. The bored cylinder should arrive this week or next, so it's time to tear down the top end. This is the first time ever I've taken an engine apart, so I'm not one of those who can look at the parts and tell whether things are in good shape or not. All I know is there isn't anything obvious, like holes and chunks and bent parts. Here's want the cam looks like. Seems okay to me. I think I've talked myself into a stage 1 cam, though. Oh Lancer...! http://i280.photobucket.com/albums/kk182/motobuddha/f8b2fd7e.jpg http://i280.photobucket.com/albums/kk182/motobuddha/6591477a.jpg http://i280.photobucket.com/albums/kk182/motobuddha/01532171.jpg And here are the bearing surfaces in the head: http://i280.photobucket.com/albums/kk182/motobuddha/1c51feb1.jpg http://i280.photobucket.com/albums/kk182/motobuddha/4fc3f5e8.jpg http://i280.photobucket.com/albums/kk182/motobuddha/b82a1c00.jpg Considering this bike had sat a few years, I didn't know what to expect when I popped the head. Other than carbon buildup, everything looks fine. I might have someone who knows more than me check the valve seats and such. http://i280.photobucket.com/albums/kk182/motobuddha/d17d1b21.jpg http://i280.photobucket.com/albums/kk182/motobuddha/7b894032.jpg http://i280.photobucket.com/albums/kk182/motobuddha/67706e86.jpg http://i280.photobucket.com/albums/kk182/motobuddha/6435e896.jpg And nothing shocking about the piston. http://i280.photobucket.com/albums/kk182/motobuddha/5c479c08.jpg There it is, naked piston in the breeze. Also, a peek into the crankcase. http://i280.photobucket.com/albums/kk182/motobuddha/9e105e0d.jpg http://i280.photobucket.com/albums/kk182/motobuddha/22faaec1.jpg (Don't worry, the opening to the crankcase has been covered to keep crap out.) |
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Title: Re: The project begins Post by justin_o_guy2 on 02/13/11 at 12:12:07 Soeone may be abl to tell you where to measure & what to hope for in the am journals, or maybe you could plastigauge it. |
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Title: Re: The project begins Post by verslagen1 on 02/13/11 at 12:28:16 3C2325223F3809390931232F64560 wrote:
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1182464837/15#15 |
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Title: Re: The project begins Post by ralfyguy on 02/13/11 at 18:59:54 I think the engine parts look great. How are the tappets looking? |
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Title: Re: The project begins Post by justin_o_guy2 on 02/14/11 at 02:18:41 you are going back with new chain guides, right? Is the connecting rod showing rust? Clean is nice, oily is good too. |
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Title: Re: The project begins Post by MotoBuddha on 02/14/11 at 04:31:00 5D4244435E5968586850424E05370 wrote:
When I got the bike, it had been sitting a few years and the crankcase had filled with gasoline. So when I drained it it didn't leave much in the way of oily residue behind. Guess I could spritz some oil around in the crankcase. |
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Title: Re: The project begins Post by MotoBuddha on 02/14/11 at 05:12:08 "Hit it with a hammer" is supposed to be the joke solution for mechanical problems, right? So I got a little perverse satisfaction thumping on the head and cylinder with a rubber dead blow mallet in order to losen them. However, it seemed so wrong hitting a screw driver with a framing hammer in order to bend back the locking tabs on the cam shaft sprocket bolts. |
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Title: Re: The project begins Post by justin_o_guy2 on 02/14/11 at 07:13:51 However, it seemed so wrong hitting a screw driver with a framing hammer in order to bend back the locking tabs on the cam shaft sprocket bolts. Well, thats because it IS wrong. But, ya gotta make do with what ya got & that works. As your tool collection grows, you'll want some chisels of different thicknesses & punches & a ball pein or 2. I didnt know not to hit hammer on hammer when I was 18. Was changing Ujoint, had no punches, no vise, just wrenches, a driveway & 2 hammers. I wound up with a piece of hammerface in my right hand, up by my thumb main knuckle. Air Force Doc said, we gotta leave it in there, its too deep & too close to major nerves to go get it. Over the years, it migrated down between th big knuckle & the one down by the thumbnail. I was working on a car with a hot engine & got it against the exhaust manifold. Didnt take much cutting to get it out after that burn healed up. Anyway, Never smack a hammer with hammer.. |
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Title: Re: The project begins Post by MotoBuddha on 02/14/11 at 08:39:48 26393F3825221323132B39357E4C0 wrote:
I think Mythbusters did a thing on that. As far as bending back lock tabs goes, I thing the "proper" tool would be something like a wrench socket but with the six chisel shaped edges. Each edge would be more slanted than the next, You'd slip the "socket" onto the bolt head or nut with the thinnest angle lined up with the tab. Give it a hit to pry back the tab a bit, then rotate the "socket" to the next flatter angle. Repeat until the tab is flat. Oh, sure, you'd need a different wedge "socket" for each bolt size, but... ;D |
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Title: Re: The project begins Post by justin_o_guy2 on 02/14/11 at 08:47:52 I started the bend on mine with a wood chisel, soon as it was out far enough ( about 1/8th") I went to a cold chisel, then went to a punch & walked it out nice & easy like, More light taps works better than a couple of Big Smacks. Its bad form, I know, but I sometimes use my body hammer, cuz its lite & I can deliver quick taps. Learning how to hold a chisel is good, too. Palm toward the chisel will cut down on those knuckle mashin misses. If you have to use a bigger hammer & swing hard, hold a punch with vise grips. I cant speak to Mythbusters results, but I can show ya the scar. Wish I still had the hammer with the little pieces missing around the edge of the face. Looking back,, Il bet I had to borrow a hammer. No way I owned 2 of the same kind of tool back then. No way I owned 2 1 pound ball piens. |
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Title: Re: The project begins Post by verslagen1 on 02/14/11 at 11:21:07 5D7F647F526574747871100 wrote:
I think Mythbusters did a thing on that. As far as bending back lock tabs goes, I thing the "proper" tool would be something like a wrench socket but with the six chisel shaped edges. Each edge would be more slanted than the next, You'd slip the "socket" onto the bolt head or nut with the thinnest angle lined up with the tab. Give it a hit to pry back the tab a bit, then rotate the "socket" to the next flatter angle. Repeat until the tab is flat. Oh, sure, you'd need a different wedge "socket" for each bolt size, but... ;D [/quote] mythbuster did do it, they weren't able to get to modern hammers to fracture. and moto... you gotta be kidding me. ::) |
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Title: Re: The project begins Post by sexysavage on 02/14/11 at 11:27:05 I just registered on this forum, but I have been following your build from the beginning. Can't wait to see what you do next. I have been researching diffrent bikes to turn into a bobber and this I think is hands down the one to go with. Keep up the good work and keep the pics coming! |
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Title: Re: The project begins Post by MotoBuddha on 02/14/11 at 12:12:51 594A474D524C5E522B0 wrote:
Like this: http://i280.photobucket.com/albums/kk182/motobuddha/d554c533.jpg http://i280.photobucket.com/albums/kk182/motobuddha/a7363524.jpg |
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Title: Re: The project begins Post by ralfyguy on 02/14/11 at 15:40:03 IMHO all the critical parts look very healthy. |
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Title: Re: The project begins Post by MotoBuddha on 02/14/11 at 15:45:38 The bike had less than 9K miles on it, so it should be in good condition. It's just that the way it had been neglected on the outside, the fact it had sat for a long time, a crankcase full of gas, and the general, oh, slovenliness of the previous owners, had me fearing things would be worse. |
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Title: Re: The project begins Post by MotoBuddha on 02/14/11 at 16:38:52 So, what's the right way to clean the carbon from the valves? http://i280.photobucket.com/albums/kk182/motobuddha/48a035e7.jpg "Right" way or not, I used some carb cleaner and a plastic bristle brush. I'm fighting the temptation to scrape the last bit of baked on carbon from the valves. (The little bubbles are some freshly sprayed WD40.) |
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Title: Re: The project begins Post by BurnPgh on 02/14/11 at 17:59:12 thats just fine. Dont get too froggy. Way better than I got mine last year. |
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Title: Re: The project begins Post by MotoBuddha on 02/15/11 at 10:00:58 Ordered a pair of these today: http://i280.photobucket.com/albums/kk182/motobuddha/c704c85d.jpg YSS E-302, 320mm long. Just a basic shock with preload adjustment. I got these instead of the Progressive shocks Ryca has in their kit. I wanted to be able to specify the spring rate, and I think they look better than the Progressive units. I don't like the chrome springs and end caps. And I suspect they weigh less. |
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Title: Re: The project begins Post by babyhog on 02/15/11 at 12:13:39 That's as good-lookin' as a shock can be, if ya ask me.... A bit pricey? |
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Title: Re: The project begins Post by MotoBuddha on 02/15/11 at 12:30:20 4340414C4E542D0 wrote:
$300 for the pair, versus about $445/pr for Works Steel Trackers, $420/pr for Hagon Type A's, $645/pr for Progressive 440's and, oh. about $3,000/pr for Ohlins. |
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Title: Re: The project begins Post by sbaugz on 02/15/11 at 12:35:37 75574C577A4D5C5C5059380 wrote:
Looks nice, might consider a set of those myself. Did you confirm with RYCA that the length of those are going to work with their kit? I think the shocks on their kit are a bit longer than the stock ones. |
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Title: Re: The project begins Post by MotoBuddha on 02/15/11 at 12:41:01 The Ryca shocks are 12.5". That's 317.5mm. The closest choices from YSS were 310mm or 320mm. I went with 320mm. My big ass will probably compensate for the extra 2.5mm or 0.098425 inches. ;D You can get them here: http://www.yssusa.com/series-eco.html I like YSS shocks. They aren't fancy, but they work well enough for the way I ride. I have a pair of their Z-series on my Kawasaki ZRX1200. http://i280.photobucket.com/albums/kk182/motobuddha/f9e3293c.jpg |
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Title: Re: The project begins Post by MotoBuddha on 02/15/11 at 15:39:43 I sent an order in today for a bunch of little items. Bolts, washers, plugs, seals... It adds up surprisingly fast. Then there were the two big items: a cam chain and new exhaust pipe. The pipe I have has gouges and rust on the bottom, pitting elsewhere, and just generally scabby looking. I'm not the pipe wrap type and it would cost more than a new pipe to properly refurbish it. What the hell, splurge. |
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Title: Re: The project begins Post by justin_o_guy2 on 02/15/11 at 16:52:47 So, what kinda muffler you got comin? |
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Title: Re: The project begins Post by MotoBuddha on 02/15/11 at 18:14:46 The one in the Ryca kit. |
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Title: Re: The project begins Post by sbaugz on 02/15/11 at 19:02:01 So how much is RYCA crediting you for the shocks? I am buying the complete kit but was thinking I would get my own shocks depending on what the credit is worth. I kinda like the looks of those YSS shocks you are buying. |
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Title: Re: The project begins Post by MotoBuddha on 02/16/11 at 04:25:48 I don't know. We haven't spoken about the details of my order. |
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Title: Re: The project begins Post by MotoBuddha on 02/16/11 at 05:41:33 332C2A2D30370636063E2C206B590 wrote:
More tools = more manly, right? http://i280.photobucket.com/albums/kk182/motobuddha/aedb266a.jpg |
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Title: Re: The project begins Post by justin_o_guy2 on 02/16/11 at 06:33:51 More tools = more likely to be able to solve a problem & not create a new one doing it. Is that your hand & some new tools? Nice lookin hammer. Remember to grind the Spankin ON end of the chisel down when the hammer strikes have bashed it into a mushroom shape. Those crown edges will fly off one day & could hurt a fella.. Blood isnt more manly. |
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Title: Re: The project begins Post by MotoBuddha on 02/16/11 at 08:04:49 Seeing as how I've gone 59 years without owning a ball-peen hammer or chisel (at least not the woodworking kind) I don't imagine I'll be using my new ones so much that the chisel will become mushroomed. But thanks for your concern. Oh wait, I forgot about my masonry chisel and 3 pound sledge. Not so useful for bending back lock tabs, though. At least not on something the size of a motorcycle. A semi, maybe. http://i280.photobucket.com/albums/kk182/motobuddha/eefc278b.jpg ;D |
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Title: Re: The project begins Post by justin_o_guy2 on 02/16/11 at 08:18:11 Dude, Ive got hammers I dont always swing as hard as I can. I woulda used that hammer & chisel. |
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Title: Re: The project begins Post by MotoBuddha on 02/16/11 at 08:30:00 Now that looks better. http://i280.photobucket.com/albums/kk182/motobuddha/efcaa320.jpg The head is next after some more degreasing. |
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Title: Re: The project begins Post by Bubba on 02/16/11 at 08:34:35 Dude, your bike is gonna be super duper sparkly when you're done! Personally, I'd probably never ride it (or very little) for fear of getting it dirty... ;) |
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Title: Re: The project begins Post by MotoBuddha on 02/16/11 at 08:41:04 I'll ride it only occasionally. I mostly ride the ZRX (see above). |
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Title: Re: The project begins Post by MotoBuddha on 02/16/11 at 08:46:03 2C3335322F2819291921333F74460 wrote:
It's kind of large and blunt for the cam sprocket bolt lock tabs, don't you think? |
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Title: Re: The project begins Post by verslagen1 on 02/16/11 at 11:32:38 6E4C574C615647474B42230 wrote:
Looks great, how did you clean it? |
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Title: Re: The project begins Post by MotoBuddha on 02/16/11 at 12:10:22 Engine cleaner, dishwasher, engine cleaner, rinse, Dremel fiber cone in some spots, 409, rinse, hair dryer, engine primer, engine paint. Or I could have taken it to a soda blaster and saved the first eight steps. But where would the "fun" have been in that? |
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Title: Re: The project begins Post by MotoBuddha on 02/16/11 at 17:22:03 More tool misuse. I was trying to get the intake boot off the cylinder head. It's just two Phillips screws, so it should be easy, right? No. I got out my #2 JIS Phillips screw driver and... The screws weren't budging and the heads were in danger for stripping. Push down harder and twist... Nope. Fortunately (or maybe by design -- who knows) the screw heads have some nice flat shoulders. So get the pliers, grab the screws from the side, squeeze, turn and... Bingo! |
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Title: Re: The project begins Post by MotoBuddha on 02/17/11 at 04:57:37 Last night I dreamed I worked in an office with an attached garage where I kept this project bike. One day another Savage owner came by to see what I was doing with the bike. We went out to the garage and it had been cleaned up. All the other non-bike stuff had been moved around and some large items had been removed. I looked for my frame but all I could find were 3-to-4-inch pieces of it. I freaked out and marched back into the office to find the 20-something guy who had cleaned the garage. He shrugged and admitted cutting up my frame. I swore at him, telling him he had no right to do that. He said he didn't think the frame was good enough and that I should drop the engine into a sportbike frame. I screamed at him some more and my voice got higher and squeakier until I sounded like a little kid. He rolled his eyes and said, "Whatever, old man." I stormed back to the garage and woke up. Hmmmmm, maybe I worry too much about this project. :-? ;D |
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Title: Re: The project begins Post by kernel ken on 02/17/11 at 09:46:22 >:( Tonight take your ball peen hammer to bed with you. And, if that smart mouth whippersnapper shows up again use the hammer to adjust his attitude. You might also move the alarm clock and lamp to the back of the night stand before you go to sleep...just in case you miss him on the first few whacks. ;D |
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Title: Re: The project begins Post by MotoBuddha on 02/18/11 at 05:37:40 Well, this won't work. http://i280.photobucket.com/albums/kk182/motobuddha/8b55ac06.jpg At least not like it is. Too narrow at the base. Some bending and banging might make this fork brace wide enough, but I have a different one on the way. |
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Title: Re: The project begins Post by justin_o_guy2 on 02/18/11 at 06:39:57 It would take some heat & skill to "adjust" that & not have it look like total crap. |
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Title: Re: The project begins Post by MotoBuddha on 02/18/11 at 06:56:43 Yeah, so I have this one coming. I was able to confirm it's the correct width. http://i280.photobucket.com/albums/kk182/motobuddha/fdd75e2a.jpg The hole spacing might be off, but it's not a big deal to weld over the old ones and drill new ones. |
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Title: Re: The project begins Post by justin_o_guy2 on 02/18/11 at 08:23:39 As long as you dont need to scoot over Half a Hole, cuz drillin weld out is no easy task. |
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Title: Re: The project begins Post by MotoBuddha on 02/18/11 at 08:32:17 Ooooooooooooooo, fresh mechano-porn! The cylinder just arrived from Bore-Tech. Hello 694cc's. http://i280.photobucket.com/albums/kk182/motobuddha/016eefd5.jpg |
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Title: Re: The project begins Post by MotoBuddha on 02/18/11 at 08:33:24 3A252324393E0F3F0F37252962500 wrote:
In which case I skip the filling and just make a slot. |
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Title: Re: The project begins Post by greenmonster on 02/18/11 at 08:39:31 You really shouldn't post pics like that on a forum I visit while at work. :-[ |
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Title: Re: The project begins Post by MotoBuddha on 02/18/11 at 11:21:02 One of the advantages of working from home is that I can play with my toys. I placed the rest of the top end somewhat in place to pretend it's actually assembled. http://i280.photobucket.com/albums/kk182/motobuddha/71d31c32.jpg The head hasn't been painted yet (a lot of masking to do). It will be silver. I went with black on the cylinder to mimic old iron cylinders. And though I won't be able to see much of the valve adjustment covers, I wouldn't be happy unless I polished them. |
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Title: Re: The project begins Post by sbaugz on 02/18/11 at 11:42:34 wow, that's beautiful. |
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Title: Re: The project begins Post by MotoBuddha on 02/18/11 at 12:14:43 Another double delivery day! Direct from the other side of the planet, 1" grips without metal. And, just like it should be, the ID of the throttle side is larger. Ready for when the clip-ons arrive next week. http://i280.photobucket.com/albums/kk182/motobuddha/1666b8fe.jpg It's funny that a rubber item would come packed in bubble wrap. |
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Title: Re: The project begins Post by kimchris1 on 02/18/11 at 12:21:19 OO sooo purdy.. Like I have said before, this thread keeps my interest, it keeps getting better and better. :) kim |
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Title: Re: The project begins Post by MotoBuddha on 02/18/11 at 12:53:57 Wow, it's a hat trick Friday. Fed Ex brought the cylinder, USPS brought the grips and now UPS delivered my new shocks. http://i280.photobucket.com/albums/kk182/motobuddha/e03b0cc8.jpg That was fast turnaround. Now I just need to figure out how to get the stickers off without disassembling the shocks. I hate logos. |
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Title: Re: The project begins Post by EJID on 02/18/11 at 12:56:28 Today's your day man! Go buy a lottery ticket!!! ;D |
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Title: Re: The project begins Post by babyhog on 02/18/11 at 12:59:33 6D4F544F625544444841200 wrote:
WD-40 and tweezers... |
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Title: Re: The project begins Post by crackmonkey on 02/18/11 at 16:11:04 blowtorch and hairspray...... no i am just kidding i love when i get packages.... i would really love getting those packages.... keep up with the progress |
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Title: Re: The project begins Post by justin_o_guy2 on 02/18/11 at 16:26:28 silver tape |
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Title: Re: The project begins Post by kimchris1 on 02/18/11 at 21:15:46 How about goo gone and Q-tips? |
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Title: Re: The project begins Post by engineer on 02/19/11 at 15:15:18 Those shocks look classy, nice machine work. I see now why they cost more money than the ordinary shock. |
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Title: Re: The project begins Post by MotoBuddha on 02/20/11 at 07:06:51 Some bike buddies stopped by yesterday and gave their nods of approval on the project, though one was skeptical that raising the rear with longer shocks while dropping the front with shortened forks will give the Savage "decent handling in the twisties." My response: it will be a big improvement over what it was, and who said anything about twisties? |
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Title: Re: The project begins Post by MotoBuddha on 02/20/11 at 12:36:47 Who is that masking man? http://i280.photobucket.com/albums/kk182/motobuddha/c42daf97.jpg Getting the head ready to paint. |
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Title: Re: The project begins Post by MotoBuddha on 02/20/11 at 15:33:45 Small mystery. These are the exhaust bolts. Why does one have a depression in the head and the other doesn't? http://i280.photobucket.com/albums/kk182/motobuddha/19ea85b1.jpg And then there's the white crud on my rotor bolts. It came off with a ScotchBrite pad, but still... If it was thread lock, what was it doing on the face of the bolt? Or was it another of the PO's decorating ideas? Oh well. http://i280.photobucket.com/albums/kk182/motobuddha/c1ca39fb.jpg |
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Title: Re: The project begins Post by justin_o_guy2 on 02/20/11 at 17:21:30 Dent in bolt head, possible rock from front tire? Whn new, the bike had white paint on some bolt heads. I think t was how the factory knew things were torqued. |
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Title: Re: The project begins Post by MotoBuddha on 02/21/11 at 09:36:19 I've removed the stickers from the shocks using babyhog's tweezer and WD-40 technique. Fortunately, the plastic of the stickers was strong enough not to rip, so once I got hold of a corner the rest came along peacefully. The only trouble was that one of the stickers left its silver backing behind. It cleaned off, but it was an annoyance. http://i280.photobucket.com/albums/kk182/motobuddha/1b1417d3.jpg. Oh, and a closer look at the stickers revealed YSS is in Thailand (its US operation is in NJ). |
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Title: Re: The project begins Post by babyhog on 02/21/11 at 11:36:05 Glad that worked for you. I had a sticker on the top of a kitchen stove years ago. Washed it and scrubbed it, but didn't want to scratch the surface, so I just kept soaking it, but it never would come completely off until someone suggested WD-40. Tried it and it slithered right off. I've used it for many a stubborn sticker since. |
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Title: Re: The project begins Post by MotoBuddha on 02/22/11 at 12:24:24 Shipment of goodies arrived this afternoon. http://i280.photobucket.com/albums/kk182/motobuddha/39446b37.jpg Various nuts and bolts, washers, seals, cam chain, Raptor petcock, and, obviously, a new pipe. The old one was rusted and pitted. |
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Title: Re: The project begins Post by babyhog on 02/22/11 at 12:34:04 You sure are making alot of people jealous... ;) |
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Title: Re: The project begins Post by MotoBuddha on 02/22/11 at 13:51:15 It was another multiple delivery day. http://i280.photobucket.com/albums/kk182/motobuddha/8e79ec7e.jpg |
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Title: Re: The project begins Post by MotoBuddha on 02/22/11 at 15:24:35 I decided to paint the center part of the rear hub instead of driving myself any further insane trying to polish it. http://i280.photobucket.com/albums/kk182/motobuddha/e6fa3f5a.jpg |
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Title: Re: The project begins Post by sbaugz on 02/22/11 at 17:32:54 Looking good. What's the story with that fork brace? Looks nice. Did you get it to fit? Would love to see pics of it mounted up when you get a chance. |
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Title: Re: The project begins Post by MotoBuddha on 02/22/11 at 19:07:17 The holes in the brace are farther apart than the lugs on the forks. I'll need to make new holes. |
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Title: Re: The project begins Post by sbaugz on 02/25/11 at 04:23:50 I just got my own pair of daystar shock boots yesterday, just like the ones you got. Took a look at them and I think they are going to be way too long. They already look too long, and that's before the forks have been lowered. Just wondering if you found the same problem. |
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Title: Re: The project begins Post by MotoBuddha on 02/25/11 at 04:47:18 My forks are in pieces, so all I've done is slide one over a fork tube to see how snugly the folds fit in case I want to shorten the boots. There's some play (which you want, now that I think of it, so they'll slide up and down as the forks move) but I think I'll be able to use the zip ties to hold them up in some way. We'll see. I expected them to be long because they were made for dirt bikes. |
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Title: Re: The project begins Post by Southpaw on 02/25/11 at 08:09:10 I just wanted to add my two cents of appreciation for this thread. It has been most informative and well done. You've put a lot of good work in your ride and I'm sure the results will be rewarding! |
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Title: Re: The project begins Post by MotoBuddha on 02/25/11 at 16:13:03 I made the commitment today to go to an 18" front rim by ordering a tire and tube. Now I just need to do something about the rim. I'll contact Buchanan Spoke & Rim soon. |
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Title: Re: The project begins Post by justin_o_guy2 on 02/25/11 at 16:32:15 Id say you made a good call on the rear hub. No easy way to keep it clean with such short spokes. |
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Title: Re: The project begins Post by MotoBuddha on 02/25/11 at 17:17:20 The rear is going to be an 18-incher too, so at least the spokes would be longer than the stock 15-incher. |
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Title: Re: The project begins Post by justin_o_guy2 on 02/25/11 at 17:23:56 Less short, yea, but reaching in to buff & keep a high polish alive would still be quite the hassle. What color will you paint it? |
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Title: Re: The project begins Post by MotoBuddha on 02/25/11 at 18:08:21 The picture above shows I painted it silver -- same as what I painted the cylinder head. |
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Title: Re: The project begins Post by justin_o_guy2 on 02/25/11 at 19:14:34 4A687368457263636F66070 wrote:
Hmmm,, well, Ill be,, so it does! & a Fine job Of it youve done.. :) Good choice Id say. |
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Title: Re: The project begins Post by MotoBuddha on 02/26/11 at 06:41:07 More signs of neglect. Not only was the brake fluid dark brown, this is what the underside of the master cylinder lid looked like: http://i280.photobucket.com/albums/kk182/motobuddha/f719919e.jpg http://i280.photobucket.com/albums/kk182/motobuddha/38289b1d.jpg Crystalized something or other. Yum. |
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Title: Re: The project begins Post by justin_o_guy2 on 02/26/11 at 07:53:25 Thats just disgusteratin... |
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Title: Re: The project begins Post by MotoBuddha on 02/26/11 at 09:51:13 Here's today's adventure in sanding. The switch pods and controls started out looking like this, which is pretty common on older bikes: http://i280.photobucket.com/albums/kk182/motobuddha/9353b891.jpg This is after going over it with a fine grit disk in my pneumatic grinder, followed by a ScotchBrite disk: http://i280.photobucket.com/albums/kk182/motobuddha/65d991e1.jpg That got the corrosion off, as well as some of the sand cast texture, but it left sanding marks, so it was 220 grit hand sanding time: http://i280.photobucket.com/albums/kk182/motobuddha/c85125a0.jpg About half way through I considered bagging it and just painting or powder coating the pods black. But I plugged along, and now everything looks like this: http://i280.photobucket.com/albums/kk182/motobuddha/89887880.jpg It should be easier from here now that the rough surfaces are gone. Later that day: http://i280.photobucket.com/albums/kk182/motobuddha/c591704b.jpg http://i280.photobucket.com/albums/kk182/motobuddha/ee426824.jpg |
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Title: Re: The project begins Post by Serowbot on 02/26/11 at 10:08:20 Next time someone says,... "You can't make a silk purse out of a sows ear"... I'm gonna' say,... "Talk to the MotoBuddha"... :-?... |
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Title: Re: The project begins Post by zx6chris on 02/26/11 at 13:37:29 Hi there I'm a newbi here and I'm restoring an 87 savage and was wondering how u took the switch gear apart more to the point the starter switch :) |
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Title: Re: The project begins Post by MotoBuddha on 02/26/11 at 15:20:01 I just unscrewed things. I hope I can figure out how it all goes back together. :-/ |
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Title: Re: The project begins Post by Serowbot on 02/26/11 at 15:58:44 ... always the tricky bit... :-?... |
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Title: Re: The project begins Post by MotoBuddha on 02/27/11 at 07:01:43 When Suzuki made the hubs on the Savage, they decided to leave the casting ridges that run from one side of the hub to the other, like this one: http://i280.photobucket.com/albums/kk182/motobuddha/df6f17f8.jpg But here's a hub from a lowly '70s GS450. As you can see, they at least made an attempt to get rid of the casting marks. http://i280.photobucket.com/albums/kk182/motobuddha/12b4ed84.jpg The overall casting seems better, too, with no flash or voids. Ah, the good old days. |
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Title: Re: The project begins Post by jandaso on 02/27/11 at 09:33:27 Would you mind telling me what are you using to clearcoat the forks an the engine covers. I'm going to sand the parts and polish them. |
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Title: Re: The project begins Post by MotoBuddha on 02/27/11 at 10:11:09 My pro bike painter buddy will be spraying them with clear. |
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Title: Re: The project begins Post by MotoBuddha on 02/27/11 at 13:02:06 I had worked a little before on smoothing out the welds on the front Y. I went back at it today with a file. http://i280.photobucket.com/albums/kk182/motobuddha/d428b20e.jpg Then I went over it with a sanding disk. http://i280.photobucket.com/albums/kk182/motobuddha/f408f18a.jpg By the time it's sand blasted, it should look pretty good. I'm not going for show quality, just cleaner looking. A quick and dirty coat of black just to see how it's going. http://i280.photobucket.com/albums/kk182/motobuddha/af468c7b.jpg |
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Title: Re: The project begins Post by Hades on 02/27/11 at 14:43:32 Can't wait to see the finished product! :D |
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Title: Re: The project begins Post by MotoBuddha on 02/27/11 at 15:51:21 I got out the triple trees to see what I need to do to refurbish them. They weren't bad, just some dull spots. It would be a lot of work doing everything just for some small spots, particularly on the chrome. Then it hit me: the triple clamps on vintage bikes were black. I'll just powdercoat them. Problem solved. |
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Title: Re: The project begins Post by Hades on 02/27/11 at 18:36:25 The contrast will look great with the triple trees in black! |
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Title: Re: The project begins Post by justin_o_guy2 on 02/27/11 at 21:29:42 Man, those little sanders use a lot of air. YOu either have a good compressor or youre spending a lot of time waiting on a compressor to get air built up. |
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Title: Re: The project begins Post by MotoBuddha on 02/28/11 at 04:23:33 I do a lot of waiting. ;D |
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Title: Re: The project begins Post by justin_o_guy2 on 02/28/11 at 05:02:56 Yeaa,,, me too. I only run the die grinder when I have no option. I sure would like a fat 2 stage, belt driven compressor head on a 100 gallon tank with a High Duty cycle motor u there spinning away, instead of this $150.00 Harbor Freight, 30 gallon, 1/3rd HP thing. I cant even air the big tire on the backhoe up from 20 to 25 without the compressor kicking in. I shut down when it kicks in, cuz I dont want to burn the poor thng up. |
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Title: Re: The project begins Post by MotoBuddha on 02/28/11 at 09:28:29 Mine's one of these. Less capacity, but less time to build pressure back up. http://i280.photobucket.com/albums/kk182/motobuddha/2f154964.png |
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Title: Re: The project begins Post by MotoBuddha on 02/28/11 at 15:54:26 I got the notice today that my Ryca production slot has opened, so the beginning phase is about to shift to the completion stage. It will take them a while to mod my tank. I'm getting things in bare metal and my pro painter buddy will be laying down the color. I won't be reassembling the engine until I get the stage 1 cam back. I also need to get the front hub re-laced to a rim. That's being held up by my experiment in upgrading to a 2-piston caliper. So, once parts start arriving, I'll finish this thread and start one with the completion stage. |
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Title: Re: The project begins Post by justin_o_guy2 on 03/01/11 at 02:39:54 A portable air tank for airing up tires would allow you to increase your volume for cheap and still be able to disconnect it & haul it to the car to top off a tire. Plumb a Milton fitting onto it & couple your POrter/Cable to it by threading a couple of male fittings together to fit between them & run your hose off the portable tank. $30.00 & a half hours work & you could have another 10 gallons of volume And a portable air tank. Youd wait longer, but you could work a bit longer. IDK how that would affect the life of the compressor, tho, if at all. |
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Title: Re: The project begins Post by IN-S40 on 03/01/11 at 08:02:24 I do a fair bit of wood working and use my compressor quite a bit. I started with a pancake compressor like MotoBuda and plumbed in one of thoes portable air tanks. It will work but the motor and compessor on the smaller compressors just are not built to run the amount of time to fill the extra capacity. Two compressors later and I now have a small 2 stage 30 gallon belt driven oil filled compressor, and I can actually hear myself think when its running too. That said i do still keep a small pancake compressor around for the little jobs not close to the main compressor. Darren IN-S40 |
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Title: Re: The project begins Post by MotoBuddha on 03/01/11 at 09:04:44 One annoying thing about my little compressor is that the vibration makes it turn in circles which winds up the cord and hose. I found it will hold still if I get two of the feet in the expansion gap between the driveway and garage floor. Otherwise, in cold weather, I have to keep a foot on it. Oh well, it's not like I use it a lot. |
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Title: Re: The project begins Post by MotoBuddha on 03/01/11 at 13:35:36 Big delivery day today. Most significant is the fork kit from Ryca. Left to right are the stiffer springs, the damper rod tool (which I don't need because I already made my own) with the spacers, the aluminum bars for the clip-ons and the clips for the clip-ons. http://i280.photobucket.com/albums/kk182/motobuddha/56b8098d.jpg I decided to go with an 18" front wheel -- because I like the look of the front and rear rims being the same diameter, and to drop the front another half inch. So the tire, tube, spoke tape, rim savers and tire irons arrived. http://i280.photobucket.com/albums/kk182/motobuddha/c0bbc3d2.jpg Then for next year's project bike, a fantastic '60s vintage Cushman seat arrived. All steel, delightfully scabby paint, as wide as my butt, and, as luck would have it, the nose of the bracket lines up perfectly with the seat/tank cross piece on the frame. There are some springs that I won't be using, since I believe in shock absorbers. I don't know how the rubber block worked originally, but I won't be needing that either. http://i280.photobucket.com/albums/kk182/motobuddha/1e1e1ac3.jpg Imagine, if you will... http://i280.photobucket.com/albums/kk182/motobuddha/a1561f41.jpg |
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Title: Re: The project begins Post by randyradio on 03/01/11 at 13:43:36 Oh Yea motobuddah, I'm right behind you and feeling daunted by this building a Ryca thingie. What tire, size and model is the front tire? I've got a extra font hub and would like to do the same maybe. Are you doing your own spoke lacing? |
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Title: Re: The project begins Post by MotoBuddha on 03/01/11 at 13:48:14 I'm going to send the hub off to Buchanan Spoke & Rim to be laced up to one of their shouldered Excel rims (polished, of course). Stainless steel spokes with nickel plated nipples. The tire is the same model as the one Ryca monts on the rear, a Kenda K671F, but 90/90-18 size. |
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Title: Re: The project begins Post by s40fan on 03/01/11 at 16:39:23 I was thinking of getting an 18 wheel too, but with black powder coated rims. Still on the fence though. |
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Title: Re: The project begins Post by justin_o_guy2 on 03/01/11 at 19:55:09 7C717C5B5E4D4D5A513F0 wrote:
I was afraid O that.. Tell me more bout th 2 stage compressor,, |
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Title: Re: The project begins Post by MotoBuddha on 03/02/11 at 10:10:32 The tank, the rear hub and a cashier's check for the first half payment posing at the shipping store before their schlepp to the opposite coast. Bon voyage! http://i280.photobucket.com/albums/kk182/motobuddha/cc2f4316.jpg |
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Title: Re: The project begins Post by randyradio on 03/02/11 at 13:37:47 Motobuddah, So today your tank and hub heads out to LA for the Ryca build startup. How Long are they telling you it will take to get your items back to you over here in the east? I'm excited for you and heck you're bout a big bro to us all anyways... |
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Title: Re: The project begins Post by MotoBuddha on 03/02/11 at 15:13:12 I didn't ask about turnaround, but I'm guessing a couple of weeks. |
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Title: Re: The project begins Post by justin_o_guy2 on 03/02/11 at 16:56:00 What are the plans for that tank? |
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Title: Re: The project begins Post by MotoBuddha on 03/02/11 at 17:05:45 The old Yamaha tank? A frankenbike next year. |
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Title: Re: The project begins Post by justin_o_guy2 on 03/02/11 at 22:49:44 No, I was asking about the Savage tank, looked bent a little,, they gonna straighten it? |
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Title: Re: The project begins Post by MotoBuddha on 03/03/11 at 04:37:20 I'm having Ryca just give me the tank back in bare metal. Then my paint guy will install a flush mount gas cap and do the bodywork. In fact, I'm getting all the Ryca parts, like the rear-set mount and battery box, in bare metal since I'll be doing the frame in a color other than black. |
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Title: Re: The project begins Post by Gentlemanjim on 04/18/13 at 23:57:12 You are doing the lowly Savage proud. Keep the post alive you have any fans here. |
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Title: Re: The project begins Post by Dave on 04/19/13 at 05:15:33 It would be nice to get an update......or conclusion to this project. The last post by the author was more than 2 yaars ago. Maybe his fingers are still healing from all that sanding and polishing! |
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Title: Re: The project begins Post by ToesNose on 04/19/13 at 08:40:08 Hopefully he's just having too much fun riding it to be bothered ;D Was a nice looking project though...... |
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Title: Re: The project begins Post by caseyLA on 04/19/13 at 12:12:38 Yeah what happened to Moto? Did he burn out? Did he get stuck on something and abandon the project? Did he build the world's most epic CS-1 and doesn't show us for fear of our minds melting? Moto! If you're stuck on something, contact us and let's get your project finished! |
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