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SuzukiSavage.com
/cgi-bin/YaBB.pl General Category >> Rubber Side Down! >> Project Bonnie Blue: Phase 1,2 & 3 (new pics) /cgi-bin/YaBB.pl?num=1342042892 Message started by splash07 on 07/11/12 at 14:41:32 |
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Title: Project Bonnie Blue: Phase 1,2 & 3 (new pics) Post by splash07 on 07/11/12 at 14:41:32 Well She is finally done, buttoned it up last night and took her for her first victory lap. To catch everyone up; Bonnie Blue is a 2000 Savage that I have owned for about 9 years. Started life as a bright yellow stock beast. Took me all of 5 minutes to start cutting stuff off. ;D I had some mechanical issues back about a year and a half ago that caused my engine to puke oil from the crankcase breather at an alarming rate. What I later assumed to be from a faulty petcock that was allowing gas to overfill the crankcase. Well, rather than just fix it and give it a good rinsing to remove all the puked oil, i decided to just rebuild her. Rather than start a build and make you all read and wait years for updates (I have seen some builds here go longer than 4 years) I am going to release my build all at once. Well sorta, I am going to release it over the next week or so. Complete with pictures along the way, lessons learned, advice, and a few good stories. We start the build with the tear down, This is how it looked when I finally decided to start fixing it. Notice my shop is a mere one sided shed with no electricity. Mosquitos are a rather large concern in this shop. http://https://i.imgur.com/VJLz0Ov.jpg A view of the exhaust valves after sitting for a while open to the elements. Yes, that is a spider living in there. http://https://i.imgur.com/4E631Nw.jpg Some of you may remember this shot. No its not a shot of whisky, its the amount of fluid found in the brake system. I guess the brakes can work with just air. http://https://i.imgur.com/IP0sO20.jpg This is the set up I used to prep most parts, simple stuff, and a few shots of the straining process needed when using play sand. http://https://i.imgur.com/dWYeVVE.jpg http://https://i.imgur.com/IJ45CWD.jpg http://https://i.imgur.com/YO0g6It.jpg For some reason the front brakes were plagued with problems throughout this build. I wanted them to be set apart from the croud so I went with painting the front caliper and rotor spokes. http://https://i.imgur.com/N7YNoHz.jpg http://https://i.imgur.com/o3BrsQ2.jpg http://https://i.imgur.com/tGf75WU.jpg http://https://i.imgur.com/LdPOvMA.jpg http://https://i.imgur.com/xp8AXOm.jpg After baking in the oven. http://https://i.imgur.com/QgXX3rC.jpg While I had the engine torn apart I went ahead and added a verslavy, cuz why not, right? I also lapped the valves but i didnt take any pictures of that process, sorry guys, I dropped the ball there. I will be doing an "86 soon though so I will have a chance to redeem myself. http://https://i.imgur.com/okhU9Jp.jpg Next i did the engine. Same procedure, sand blast, wash, scuff, paint, cure. Note all the opening have been plugged with rubber bungs. I used high temp grill paint for this. Came out great I think. http://https://i.imgur.com/v38ay2P.jpg http://https://i.imgur.com/fGCTxvK.jpg http://https://i.imgur.com/8OLcUbU.jpg http://https://i.imgur.com/XCksKWI.jpg http://https://i.imgur.com/C4gTlIv.jpg http://https://i.imgur.com/XjnzCM4.jpg http://https://i.imgur.com/tV8mub4.jpg http://https://i.imgur.com/xKNNaXe.jpg http://https://i.imgur.com/HT2KrRL.jpg Which brings us to the beginning of last winter. I couldnt keep working in the shed because it was too cold for this southerner, and the mosquitos were year round inhabitants. So I did what any logical, single, 27 year old man would do, I brought the project into the comfort of my bedroom. http://https://i.imgur.com/YGXu8KV.jpg http://https://i.imgur.com/sBPViPC.jpg All the parts were bagged, labeled, boxed, and stored on a shelf in the corner. This is what my night stand might look like on any given night. http://https://i.imgur.com/cCI8BQP.jpg This is what I woke up to everyday since then. (Spoiler alert) http://https://i.imgur.com/SQubik5.jpg I guess that is about enough for today, I will get Part 2 up tomorrow, which will be more front brake fun, polishing, and picking painters. See y'all down the road |
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Title: Re: Project Bonnie Blue: Phase 1 Post by Serowbot on 07/11/12 at 14:51:25 This is like the movie serials of the 1930's..... complete with a teaser at the end... Sure hope the hero wins this one... ;)... http://upload.wikimedia.org/wikipedia/en/thumb/0/0f/Adventures_of_captain_marvel.jpg/220px-Adventures_of_captain_marvel.jpg |
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Title: Re: Project Bonnie Blue: Phase 1 Post by splash07 on 07/11/12 at 14:52:47 God I used to love captain marvel, I still have a 12 VHS tape collection some where. |
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Title: Re: Project Bonnie Blue: Phase 1 Post by Badass94Cad on 07/11/12 at 16:55:06 More more MORE!!! :) |
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Title: Re: Project Bonnie Blue: Phase 1 Post by ToesNose on 07/11/12 at 19:23:02 Woots! Great stuff ;) |
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Title: Re: Project Bonnie Blue: Phase 1 Post by justin_o_guy2 on 07/11/12 at 19:49:56 A short pipe nipple screwed into the caliper threaded holes woulda made masking quicker. & theyre chip,, Or are those things not NPT? |
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Title: Re: Project Bonnie Blue: Phase 1 Post by Cavi Mike on 07/11/12 at 20:19:16 No brakes use pipe-threads. They use flares, compression fittings or gaskets to create a seal. Pipe-threads are actually very poor at creating a seal which is why they require teflon tape or some other thread-sealing alternative. |
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Title: Re: Project Bonnie Blue: Phase 1 Post by verslagen1 on 07/11/12 at 21:08:35 carefull getting it thru the door, wouldn't want you to chip the paint. ;D looks like building a ship in a bottle. |
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Title: Re: Project Bonnie Blue: Phase 1 Post by justin_o_guy2 on 07/11/12 at 21:48:45 4F6D7A65416567690C0 wrote:
I wasnt expecting it to work the brakes, if itll screw in & not do damage ( finger tite is plenty) then the paint wouldnt have those areas not covered because of the tap[e, |
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Title: Re: Project Bonnie Blue: Phase 1 Post by thumperclone on 07/11/12 at 22:14:52 droolin here 8-) |
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Title: Re: Project Bonnie Blue: Phase 1 Post by splash07 on 07/12/12 at 10:55:32 7D6264637E7948784870626E25170 wrote:
I wasnt expecting it to work the brakes, if itll screw in & not do damage ( finger tite is plenty) then the paint wouldnt have those areas not covered because of the tap[e, [/quote] Thats not a bad idea actually. I will be repainting the caliper this weekend because I got a lot of brake fluid on it during the bleeding process (more info on that soon) and some of the paint did come off. I might try using ear plugs to, they compress down and then expand slowly filling in the holes. |
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Title: Re: Project Bonnie Blue: Phase 1 Post by splash07 on 07/12/12 at 22:31:01 Part 2: As with any project there are limitations such as budget, time, knowledge (or lack of). This project was no different, each modification required funds and time, two things that are in short supply these days. So there were times when weeks might pass between wrenching sessions. All the while the project is staring me in the face and tripping me at night when I get up to pee. Stubbed toes are a constant reminder that "HEY there is a project on the floor that needs tending to!" Good motivation to get it done. Although I will say that it never hurts your rep with the ladies having a motorcycle in the bedroom ;) Back to the brakes: Something that I mentioned way back was the possibility of drilling your own brake rotor. There was not much discussion before verslagen1 had a template made up and was drilling test rotors. http://suzukisavage.com/cgi-bin/YaBB.pl?num=1338489898 Here is mine. Painted the spokes of the rotor with the same caliper paint used on the caliper. You will also note the strainless steel brake line upgrade, I am very happy with it. http://https://i.imgur.com/6fbIIcF.jpg http://https://i.imgur.com/QtKSukT.jpg Having the engine out of the frame gave me the opportunity to touch up some areas on the frame that were scratched and some rust spots, as well as give it a good cleaning. http://https://i.imgur.com/yd6Cbe1.jpg |
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Title: Re: Project Bonnie Blue: Phase 1 Post by splash07 on 07/12/12 at 22:55:37 There is a lot of great info in the tech section on polishing: http://suzukisavage.com/cgi-bin/YaBB.pl?board=tech;action=display;num=1182464837 And polishing is now one of my least favorite things to do. I went with the quik and dirty method which basically is the same as full blown polishing but with less time spent wet sanding and more time at the polishing wheel. Toothpaste works OK for cleaning stuff but its not a great polish, i recomend mothers for aluminum. I also used tal strip II aircraft stripper to remove the clear coat on all the parts first. Some stuff I re-cleared, like the forks, rear brake hub, spring mounts, and switch housing, but some I left polished only like the crankcase covers. This was because the clear can turn milky when heated and you lose that awesome shine. Here are some shots of the polishing process: http://https://i.imgur.com/3NqUdX6.jpg http://https://i.imgur.com/So8aSPR.jpg http://https://i.imgur.com/1tZejHO.jpg http://https://i.imgur.com/ruhmTvO.jpg http://https://i.imgur.com/WMHwas6.jpg http://https://i.imgur.com/mGlJ5bP.jpg http://https://i.imgur.com/tGu7aEC.jpg T-Kat fork brace installed. I had to modify the Daystar fork boots a little to get them to fit right with the brace by cutting off the bottom part where its not waffled. http://https://i.imgur.com/q8Txiuy.jpg |
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Title: Re: Project Bonnie Blue: Phase 1 Post by splash07 on 07/12/12 at 23:03:19 Previously I had accidentally cut off my CDI box shear at the connector witht the drive belt, not an easy thing to do. So I had to do some electrical wire harness surgery. I found a great kit here: http://www.easternbeaver.com/ minimum orders of 20 bucks, ships from japan. So had to take this: http://https://i.imgur.com/SqBPNX8.jpg and this: http://https://i.imgur.com/rpY70Ls.jpg and turn it into this: http://https://i.imgur.com/ueXVvj2.jpg http://https://i.imgur.com/mmOu0bp.jpg http://https://i.imgur.com/QrCBrml.jpg http://https://i.imgur.com/JP8KHXI.jpg |
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Title: Re: Project Bonnie Blue: Phase 1 Post by splash07 on 07/12/12 at 23:08:24 Progess is made: http://https://i.imgur.com/l6TPxMC.jpg And like magic!!!!!! http://https://i.imgur.com/WzcTCPO.jpg Parts pile gets smaller and time marches slowly on: http://https://i.imgur.com/L6ovsw1.jpg http://https://i.imgur.com/NOHW4b8.jpg http://https://i.imgur.com/bssi6La.jpg http://https://i.imgur.com/tbekYjZ.jpg http://https://i.imgur.com/NyHXXYP.jpg As you can see I chose clubman handlebars, found on fleabay for 65 shipped, I love em. When it came time to paint, I knew I wanted something professional, no more rattle can jobs for me. So I shopped around and the best price I could find locally was $675. That was way out of my price range. I know that a great paint job can cost as much as you want it to but seriously I am not building a show bike here. So I shipped the tins to Alabama to an old friend of my dad's, I only know him as Billy Patterson's daddy. He runs a shop out of the back of his house and has a barn with a hell of a motorcycle collection, including a savage. So Billy Patterson's daddy felt sorry for me and said he would do the job for free. Huge props go out to him and his for the awesome paint. http://https://i.imgur.com/5FF2m6J.jpg Enough for today I suppose. More a little further on down the line. Part 3 will be some more front brake stuff (yay!!!!), carb cleaning and exhaust prep, and final assembly. |
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Title: Re: Project Bonnie Blue: Phase 1 & 2 Post by Badass94Cad on 07/13/12 at 05:13:39 The anticipation is killing me! ;D Real good build pics so far. 8-) |
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Title: Re: Project Bonnie Blue: Phase 1 Post by Cavi Mike on 07/13/12 at 09:05:44 081711160B0C3D0D3D05171B50620 wrote:
That has nothing to do with the threads not being NPT. NPT is its own standard and they're tapered. These are M10x1 or M10x1.25 |
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Title: Re: Project Bonnie Blue: Phase 1 Post by splash07 on 07/13/12 at 14:13:29 5B485F5E414C4A48431C2D0 wrote:
I guess you will just have to stick around til the end to find out ;D ;D ;D Captain Marvel...........Awaaaaaaaaaaay!!!!!!!!!!!! |
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Title: Re: Project Bonnie Blue: Phase 1 & 2 Post by splash07 on 07/14/12 at 15:16:30 Part 3: The saga continues, when we last left off our hero was battling the front brakes let see how he made out.... I thought I had the brakes ready to bleed when I noticed the rotor was rubbing. http://https://i.imgur.com/ZghfYkl.jpg You can see there where the rotor spokes were rubbing. :-/ it turns out that I had the washers for the caliper bracket on the wrong side, but darn if it didnt take me forever to figure that one out. Finally ready to bleed and no go. The fluid did not seem to wnat to go into the line. I ended up buying a vacuum type pump from HF on the cheap and it worked great. http://https://i.imgur.com/PhKDXwy.jpg Once I got them bled, I was ready to test em out. Squeezed on the lever and they grabed tighter than your cornhole in prison, but would not let go. So it was time for new seals in the caliper. In the process of bleeding a lot of fluid leaked onto my nice painted caliper too. http://https://i.imgur.com/GrQbDZQ.jpg Im already working on repainting it. New pads were in order as well. http://https://i.imgur.com/ifGPTQB.jpg New v. old http://https://i.imgur.com/qHpMzDf.jpg |
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Title: Re: Project Bonnie Blue: Phase 1 & 2 Post by splash07 on 07/14/12 at 15:21:17 A nice shiny new dyna and clamp bought from ebay for 20 buck ready to go. Bolted it right to the header with the harley clamp. I used two strips of tin can, the part that is corrugated, as a gasket. Seems to be working great. No backfires or pops, only a slight rumble on decel. http://https://i.imgur.com/zG3WENL.jpg I cut about 6 slots in the neck too. http://https://i.imgur.com/uZWKkd6.jpg Here is the header all wrapped in fiberglass, its main purpose is to protect my boots, since I removed those heavy heat shields. http://https://i.imgur.com/vYl6XQf.jpg All put together: http://https://i.imgur.com/oEApGqL.jpg |
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Title: Re: Project Bonnie Blue: Phase 1 & 2 Post by splash07 on 07/14/12 at 15:27:09 The carb was somewhat dissasembled to clean it and replace the jets. Here you can see how nasty it had gotten from sitting. http://https://i.imgur.com/zhcCekN.jpg Time to clean it up and get it ready: http://https://i.imgur.com/YI2pBle.jpg http://https://i.imgur.com/epOmlW2.jpg http://https://i.imgur.com/jWtMIxG.jpg |
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Title: Re: Project Bonnie Blue: Phase 1 & 2 Post by splash07 on 07/14/12 at 15:32:30 I like a little chrome ona bike or car but not too much, Most new Harleys today just look guady with all the chrome everything. So in an effort to tone the bike down I removed the chrome bar ends, but what to replace trhem with......hmmmmm.......I dont know ::) ::) Maybe a set of these: http://https://i.imgur.com/1p1MhSO.jpg Diceded on the Natural Light since the blue matched the best, i can always change out later. All I used was a dab of shoe glue and then popped em on. http://https://i.imgur.com/lS367e5.jpg and of course I only use the best parts and supplies: http://https://i.imgur.com/Z3EdF6B.jpg Final assembly went very slowly. I had a bunch of misc. unexpected expenses which slowed all my side project to nearly a halt. Which was very frustrating since I was so very close to being done. I kept telling all my friends that "it will be done in a week" and then every week it was still not done, finally I got it finished up and rolled it out of the bedroom. http://https://i.imgur.com/ykaz0fQ.jpg I was able to get it out of my room, down the hall, and out on the front porch to try and start it up without scratching paint on the bike or on the walls, whent really smooth actually. I had a little electrical hiccup that was easily fixed. Once I had spark the ole girl fired off on the first try. :D :D :D :D |
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Title: Re: Project Bonnie Blue: Phase 1 & 2 & 3 Post by splash07 on 07/14/12 at 15:41:40 Here are some preliminary shots of Bonnie Blue all done. She is missing the front fender here. I am waiting to install it when I finish painting the front caliper and get the brakes bled, I dont want any fluid getting on the fender. http://https://i.imgur.com/L8qnK72.jpg http://https://i.imgur.com/lLc9gXN.jpg http://https://i.imgur.com/W4WJpaH.jpg http://https://i.imgur.com/Os3XQle.jpg http://https://i.imgur.com/lyn9lna.jpg I have not gotten it registered yet so I could only take it around the block once or twice but it runs like a scalded dog. lean and mean!!! http://i882.photobucket.com/albums/ac30/splash07s/c85e7050.jpg |
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Title: Re: Project Bonnie Blue: Phase 1 & 2 & 3 Post by splash07 on 07/14/12 at 15:48:43 I am sorry for the poor quality of the photos I will try and get some pro shots up soon. I want to thank this forum.....Thank You suzukisavage.com Thanks to Mysterious John A big thanks to the mod squad and regulars, especially LANCER, verslagen, JOG2, oldfeller, serowbot, and everyone else who jumped in to help whenever I needed it. I know that there are a ton of others here that contributed to my success and thanks to you all. This has got to be one of the best places on the web, cycle related or not. This is an amazing bike and it comes with the best tech support in the world, avbailable 24/7 365 and its free to everyone. I just love it here. I hope you all enjoyed the build, I did not document every little detail but I do have a lot more pictures if any one is interested. Please leave me feedback on the bike and suggestions. Of course she is not really DONE. She will probably never be done. I still plan to get some matching brown leather saddlebags and saddle and a nice rifle scabbard for the front forks to hold my umbrella, i also want to lower the front end at some point. we will see, there is always a mod out there I am thinking about trying. |
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Title: Re: Project Bonnie Blue: Phase 1,2 & 3 Post by Badass94Cad on 07/14/12 at 15:58:35 Awesome build pics. Great thread. 8-) |
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Title: Re: Project Bonnie Blue: Phase 1,2 & 3 Post by ToesNose on 07/14/12 at 17:19:01 Sweet ride Splash, thanks for sharing your build :) |
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Title: Re: Project Bonnie Blue: Phase 1,2 & 3 Post by Borracho on 07/15/12 at 16:19:07 Sweet ride, you should be proud. I especially like the paint. |
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Title: Re: Project Bonnie Blue: Phase 1,2 & 3 Post by mojohand40 on 07/15/12 at 17:19:05 Looks great! Thanks for the build thread! I find these threads fascinating and inspirational. Makes me want to grab a wrench! good job. |
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Title: Re: Project Bonnie Blue: Phase 1,2 & 3 (update Post by splash07 on 07/16/12 at 18:46:15 Went for the first ride today after I got the bike registered. 75 miles on the twistiest road I could find. Ran great, seems to run best between 60 and 75, man she hauls. I almost forgot what a noisy bike we have here, but its a song, a familiar metronome that comforts as you ride. The new Dyna sounds fantastic, rumbles when you want it and does not when you dont. I stopped every 20 minutes or so to check all the common culprits for coming loose, all stayed nice and snug, brakes were there but may need bleeding one more time because it feels like there might be a little air still in there. Got the caliper repainted though and it looks good. here are a couple of pics of the bike from around the lowcountry, enjoy! http://https://i.imgur.com/OJQECa9.jpg http://https://i.imgur.com/EInJWsf.jpg http://https://i.imgur.com/niVZPnb.jpg http://https://i.imgur.com/eqay1U6.jpg http://https://i.imgur.com/ldm2Yia.jpg |
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Title: Re: Project Bonnie Blue: Phase 1,2 & 3 (new pics) Post by Kilgore Trout on 07/18/12 at 07:16:16 Very slick, Splash. I really dig the clubman bars. I have been kicking around the idea of doing something similar -- maybe some inverted flat-track bars. So maybe you can tell me ... how uncomfortable is it to ride now? |
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Title: Re: Project Bonnie Blue: Phase 1,2 & 3 (new pics) Post by splash07 on 07/18/12 at 11:07:19 The bars feel really good actually. I thought that they might bring me too far forward but I actually like the position. Feels like a more upright riding position with the option to tuck forward if you want. Also seems to make the bike seem lower than it actually is. |
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Title: Re: Project Bonnie Blue: Phase 1,2 & 3 (new pics) Post by ralfyguy on 07/18/12 at 22:01:54 I like the bars as well. Just one question: How is this with the brake fluid reservoir? It's tilted forward. Does it not leak through the vent holes? And the sight glass won't show the correct level... :-? |
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Title: Re: Project Bonnie Blue: Phase 1,2 & 3 (new pics) Post by splash07 on 07/19/12 at 13:02:20 Brake fluid reservoir seems to be OK. What vent holes are you referring to? I was of the understanding that the brake system was a closed system? Well, I have had no leaking yet. It seems to me that the master cylinder location and angle is about the same on my bars as on a RYCA. As for the sight glass; yes, it is hard to tell what the level is but all I have to do is loosen the two allen screws on the clamp housing and rotate it about 20 degrees up to get a view of the glass then I know. Mostly I just do periodic brake fluid checks, especially after discovering less than a tablespoon of fluid in there the last time. |
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Title: Re: Project Bonnie Blue: Phase 1,2 & 3 (updated pi Post by LANCER on 07/22/12 at 04:42:51 Nice shot of the bike in front of a Charleston style home. |
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Title: Re: Project Bonnie Blue: Phase 1,2 & 3 (new pics) Post by Pat on 08/05/12 at 13:30:24 I also like the bars, they look great. Pat |
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Title: Re: Project Bonnie Blue: Phase 1,2 & 3 (new pics) Post by justin_o_guy2 on 08/05/12 at 14:20:15 Too bad I wasnt there to help ya. I coulda kept ya from gettin yer bars upseide down & bakkerds,, Good lookin job, man, |
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