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Message started by Tempted on 12/07/13 at 21:11:23

Title: 86 Savage Restoration
Post by Tempted on 12/07/13 at 21:11:23

I bought this bike for my brother in-law. It was a straight up basket case but I only gave a couple hundred bucks for it with a clean title. The wiring harness was completely destroyed, the paint in terrible shape, the frame showing its age and the bike was just all around rough. It was also in pieces. When I got it home I built enough of a harness just to see if/how well it ran. Runs great, idles great, pulls hard throughout the range and the transmission/clutch is perfect. After a day of testing/tuning, we tore it down to get started. Its been a week and things are progressing a little slower than I'd hoped but I've been running between Chattanooga and Atlanta working on a hydrogen generator(I work for an alternative energy company).

So far we have stripped the tins, repaired the dents, blocked the tank and primed the frame. Tomorrow we'll be finishing the prep and spraying the tins, frame and motor. We couldn't decide on color but then found some Dodge Viper blue(very fine flake) from a past build that we'll be using. I'll be making some side covers, the bike didn't come with any and I don't like the factory ones. They leave too much of an empty hole behind the motor.

I'll be upgrading the brakes to a dual disc front, disc rear. Not only is this my brother in-law's first bike, my pregnant sister will be a passenger on it. I want to have more stopping power than we need. I'm hoping to keep the stock forks to keep cost down but I don't know that I can shoehorn in dual discs between the legs. I have a set of stock forks with triples from my 2001 ZRX1200R that I may try to use. I've also got the rear braking system from my 2007 Harley Streetbob collecting dust. The bike has a 150 15 on it now and I'd like to get a 160 back there if I can.

I'll post some updated pictures tomorrow after the tins are sprayed. If all goes as planned the bike will be on the road this coming weekend. This is my first Savage build and so far its been a joy. The machines are beautifully simple.

One thing I'm not sure about is the decompression system. When I made the harness to run the bike I bypassed it. The bike starts quickly and easily without it so I'm debating on all together ditching it to clean up the head a little. Thanks for the forum and hopefully you'll enjoy the build. I'll update daily.

Title: Re: 86 Savage Restoration
Post by Tempted on 12/07/13 at 21:15:49

http://i252.photobucket.com/albums/hh15/wvxvxvxvw/Bike/P1010018.jpg (http://s252.photobucket.com/user/wvxvxvxvw/media/Bike/P1010018.jpg.html)

http://i252.photobucket.com/albums/hh15/wvxvxvxvw/Bike/P1010046.jpg (http://s252.photobucket.com/user/wvxvxvxvw/media/Bike/P1010046.jpg.html)

http://i252.photobucket.com/albums/hh15/wvxvxvxvw/Bike/P1010047.jpg (http://s252.photobucket.com/user/wvxvxvxvw/media/Bike/P1010047.jpg.html)

http://i252.photobucket.com/albums/hh15/wvxvxvxvw/Bike/P1010050.jpg (http://s252.photobucket.com/user/wvxvxvxvw/media/Bike/P1010050.jpg.html)

http://i252.photobucket.com/albums/hh15/wvxvxvxvw/Bike/P1010051.jpg (http://s252.photobucket.com/user/wvxvxvxvw/media/Bike/P1010051.jpg.html)

Title: Re: 86 Savage Restoration
Post by verslagen1 on 12/07/13 at 21:55:02

Quote:

I'll be upgrading the brakes to a dual disc front, disc rear. Not only is this my brother in-law's first bike, my pregnant sister will be a passenger on it. I want to have more stopping power than we need. I'm hoping to keep the stock forks to keep cost down but I don't know that I can shoehorn in dual discs between the legs. I have a set of stock forks with triples from my 2001 ZRX1200R that I may try to use. I've also got the rear braking system from my 2007 Harley Streetbob collecting dust. The bike has a 150 15 on it now and I'd like to get a 160 back there if I can.

dual fronts with the stock forks will be difficult. not only does the right fork lack the mounting, but the hub lacks it too. It'll be much easier to swap something else in there. any of the gs series will bolt right in for the most part.

the rear drum while much maligned, is quite capable of locking the rear. getting a disk in there will be quite difficult too.

Title: Re: 86 Savage Restoration
Post by Tempted on 12/07/13 at 22:20:47

Yeah I became aware that the rear drum can lock up quickly when I test rode it around the block on a damp street. What I'm concerned about is that they live in the Tennessee mountains and will be riding down hills often. I'd rather have a fade-less disc. I'm not concerned about brackets, they are simple enough to fabricate, I'm not sure I'll have the room without a front end swap. I did a USD swap on my ZRX so I have a front end, just not a direct bolt on and the rake won't be as pronounced. Brakes and suspension are the two things I give the most attention to. Too much is better than too little. From all I've been able to read, the Savage is about as reliable as the sun. I'm hoping that my brother in-law will get tens of thousands of trouble free miles out of it before the next rebuild. The motor didn't need bearings, all I did was put new rings and a jug gasket on it. It didn't even need those but while the motor was out and easily accessible I assumed it would be a wise thing to do.

One thing about this bike is it makes a lot of off-the-line torque. It feels quicker to 30mph than a little Honda Magna V30(4 cylinder, 60+hp) that I just finished does. I think I can drop a few rear sprocket teeth without losing any low speed ride-ability that will decrease the highway revs.

Title: Re: 86 Savage Restoration
Post by PerrydaSavage on 12/08/13 at 02:55:12

How many miles on the motor? Cam chain tensioner might be near it's limit depending on mileage ... ya might wanna have a look see and consider swapping it it for one of Verslagen's "verslavy" modded tensioners ...

Good luck with the build and please keep us posted ... am anxious to see how this one turns out! 8-)

Title: Re: 86 Savage Restoration
Post by ToesNose on 12/08/13 at 04:26:21

Hey Tempted sounds like you started with a basket case for your build, but you seem to be up for the challenge and have a solid plan. Thanks for sharing with all of us, looking forward to watching the fun unravel ;)

Title: Re: 86 Savage Restoration
Post by Dave on 12/08/13 at 09:19:53

Unless you really just like projects and scrounging around for parts.....the stock brakes are up to the job. They can handle the power and weight of the bike. When we go to the Dragon Run in North Carolina and Tennessee and spend the week chasing Oldfeller around with some very spirited riding, we have never had any issues with the brakes. This year Oldfellor and I found a road just like the Dragon that was 30 miles long and road it non-stop.....and never once did the brakes even cross my mind.....they work fine. I think Oldfeller got his pretty hot when chasing BigZuke - but never to the point of causing any problems.

Title: Re: 86 Savage Restoration
Post by Tempted on 12/08/13 at 17:41:41

For the life of me I can not get the triples separated from the stem. I've pulled the tubes and risers but I had to tape the triples when I painted the frame because I can't remove them. I tried a small press, soaked it in tranny fluid and worked at it with a mallet for an hour to no avail. There isn't much visible rust or oxidation at the stem and the nut came off with no fuss. I don't know what the little covered lock on the stem is or how to remove it. The key doesn't fit. I assumed it to be a steering lock but would think that if this were the case it would use the same key as the ignition and fuel cap.

I need an exhaust system. The one on it was chopped up and "welded" to an un-baffled Harley muffler. Looks like they used a soldering iron as a welder. I don't own a pipe bender or flare tool that would work on a 3" pipe so I can't make one. Since there was no air box included I'm simply going to use a pod and re-jet the carb. I like how pods look anyway. I'll try to get a few pictures up tonight.

Title: Re: 86 Savage Restoration
Post by Tempted on 12/08/13 at 18:12:04

Working on smoothing the repaired dents. We pulled what we could and fiberglassed the remaining divots.
http://i252.photobucket.com/albums/hh15/wvxvxvxvw/Bike/P1010025.jpg (http://s252.photobucket.com/user/wvxvxvxvw/media/Bike/P1010025.jpg.html)

Rust proofed the underside of the fenders before the rubber undercoating was applied.
http://i252.photobucket.com/albums/hh15/wvxvxvxvw/Bike/P1010024.jpg (http://s252.photobucket.com/user/wvxvxvxvw/media/Bike/P1010024.jpg.html)

http://i252.photobucket.com/albums/hh15/wvxvxvxvw/Bike/P1010026.jpg (http://s252.photobucket.com/user/wvxvxvxvw/media/Bike/P1010026.jpg.html)

http://i252.photobucket.com/albums/hh15/wvxvxvxvw/Bike/P1010028.jpg (http://s252.photobucket.com/user/wvxvxvxvw/media/Bike/P1010028.jpg.html)

I didn't get the tins sprayed blue today like I planned. I got hung up on the triples and then worked on rust proofing and spraying the frame. More to come tomorrow.

Title: Re: 86 Savage Restoration
Post by pgambr on 12/08/13 at 18:34:26

That looks pretty good! I tried that once, it didn't come out so swell.

Title: Re: 86 Savage Restoration
Post by Dave on 12/09/13 at 04:18:53

Be sure to read this thread before you apply the finish coat. Several members of this site have attempted to paint their bikes with rattlecans and find a paint that will hold up on the gas tank. To date....the only paint that shows any ability to hold up is the 2K clear coat. All of the other paints have peeled, wrinkled or discolored when a bit of fuel is leaked from the tank or dripped while fueling.

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1384003491/0

Title: Re: 86 Savage Restoration
Post by justin_o_guy2 on 12/09/13 at 07:43:10

I couldnt use the rear brake much at all,, It would slide the tire.way too easy,

I used an angle grinder & cut grooves in the brake pads,I decreased the surface are that contacts the drum by at least 30%. I can still lock it up a little too easy, but nothing like before.

Title: Re: 86 Savage Restoration
Post by Tempted on 12/09/13 at 08:55:18

447F7265747863657E767B64170 wrote:

I'm not rattle canning it. The only thing rattle canned was the self etching primer and undercoating. My primer gun is clogged and I didn't feel like cleaning it.

Title: Re: 86 Savage Restoration
Post by Tempted on 12/09/13 at 18:01:50

Applying the first coat of Viper blue to the front fender.

http://i252.photobucket.com/albums/hh15/wvxvxvxvw/Bike/P1010035.jpg (http://s252.photobucket.com/user/wvxvxvxvw/media/Bike/P1010035.jpg.html)

First coat finished, waiting to dry so I can wet sand and apply the next one.

http://i252.photobucket.com/albums/hh15/wvxvxvxvw/Bike/P1010036.jpg (http://s252.photobucket.com/user/wvxvxvxvw/media/Bike/P1010036.jpg.html)
http://i252.photobucket.com/albums/hh15/wvxvxvxvw/Bike/P1010045.jpg (http://s252.photobucket.com/user/wvxvxvxvw/media/Bike/P1010045.jpg.html)

This is the repaired area that had some dents.
http://i252.photobucket.com/albums/hh15/wvxvxvxvw/Bike/P1010043.jpg (http://s252.photobucket.com/user/wvxvxvxvw/media/Bike/P1010043.jpg.html)
http://i252.photobucket.com/albums/hh15/wvxvxvxvw/Bike/P1010044.jpg (http://s252.photobucket.com/user/wvxvxvxvw/media/Bike/P1010044.jpg.html)

Title: Re: 86 Savage Restoration
Post by Tempted on 12/09/13 at 18:12:15

This is the rubber undercoating. I applied it before I painted the tins but forgot to post pictures in order.

http://i252.photobucket.com/albums/hh15/wvxvxvxvw/Bike/P1010029.jpg (http://s252.photobucket.com/user/wvxvxvxvw/media/Bike/P1010029.jpg.html)
http://i252.photobucket.com/albums/hh15/wvxvxvxvw/Bike/P1010031.jpg (http://s252.photobucket.com/user/wvxvxvxvw/media/Bike/P1010031.jpg.html)
http://i252.photobucket.com/albums/hh15/wvxvxvxvw/Bike/P1010032.jpg (http://s252.photobucket.com/user/wvxvxvxvw/media/Bike/P1010032.jpg.html)

More pictures to come as the build progresses.

Title: Re: 86 Savage Restoration
Post by Dfinn on 12/09/13 at 18:13:44

Looking good man!

Title: Re: 86 Savage Restoration
Post by Tempted on 12/09/13 at 18:23:44

36343B3C3C3735333C6563520 wrote:

Looking good man!

Thanks. I think this color will round out on the bike pretty well. I'm clearing all of the polished aluminum parts to get a little more pop from them when they are in the sun.

This is the paint we are using.
http://www.wallsfeed.com/wallpapers/2013/01/Blue-Dodge-Viper-485x728.jpg
http://i252.photobucket.com/albums/hh15/wvxvxvxvw/Bike/P1010036.jpg (http://s252.photobucket.com/user/wvxvxvxvw/media/Bike/P1010036.jpg.html)

Title: Re: 86 Savage Restoration
Post by Gerry on 12/11/13 at 05:12:30

4D7C74696D7C7D190 wrote:

Looking good! I would like to have the equipment to spray paint some day.
I wish you would wear a respirator though :o
Gerry

Title: Re: 86 Savage Restoration
Post by Tempted on 12/12/13 at 11:03:18

022037373C163220203129242B21450 wrote:

Looking good! I would like to have the equipment to spray paint some day.
I wish you would wear a respirator though :o
Gerry

Its much cheaper and easier than most people think. I've got two HVLP guns(one primer/clear, one paint) and one high pressure that I use when I'm spraying cheap paint on cheap cars. I have some respirators, just get lazy sometimes.

I'm using some low temp reducer because of how cold it is right now. Even in the attached garage its between 40 and 50 degrees. I always wear them when I'm clearing, that stuff is nasty. I'm using DuPont ChromaClear 4700S. Its a fantastic product, just thick and strong fumes.

I'll post some pictures of the painted and cleared tins tonight.

Title: Re: 86 Savage Restoration
Post by justin_o_guy2 on 12/12/13 at 12:18:45

Ive got some raw metal that needs paint. Its not gonna be above 50* out there. The rattlecan says not to use it below 60.. What happens if I do?

Title: Re: 86 Savage Restoration
Post by Tempted on 12/12/13 at 19:03:25

617E787F62655464546C7E72390B0 wrote:

Ive got some raw metal that needs paint. Its not gonna be above 50* out there. The rattlecan says not to use it below 60.. What happens if I do?

It will likely run, won't stick well and won't dry for a very very long time. I use low temp activator and reducer when its cold out. I also just purchased a big kerosene heater for the garage.

Title: Re: 86 Savage Restoration
Post by Tempted on 12/12/13 at 19:28:34

This stuff is pretty awesome. Its a 3-1 mix so its very thick and takes some time between coats but it looks great. Its pricey, around 300 bucks a gallon, but it goes a long ways. I'm doing 3 coats of clear on the Savage but a single coat of this stuff is usually all you need.
http://i252.photobucket.com/albums/hh15/wvxvxvxvw/Bike/P1010046-1.jpg (http://s252.photobucket.com/user/wvxvxvxvw/media/Bike/P1010046-1.jpg.html)

Spraying it from my primer gun.
http://i252.photobucket.com/albums/hh15/wvxvxvxvw/Bike/P1010051-1.jpg (http://s252.photobucket.com/user/wvxvxvxvw/media/Bike/P1010051-1.jpg.html)

Not quite dry after the first coat. I wet sanded this coat and laid a second, looks smoother.
http://i252.photobucket.com/albums/hh15/wvxvxvxvw/Bike/P1010050-1.jpg (http://s252.photobucket.com/user/wvxvxvxvw/media/Bike/P1010050-1.jpg.html)
http://i252.photobucket.com/albums/hh15/wvxvxvxvw/Bike/P1010049-1.jpg (http://s252.photobucket.com/user/wvxvxvxvw/media/Bike/P1010049-1.jpg.html)
http://i252.photobucket.com/albums/hh15/wvxvxvxvw/Bike/P1010048.jpg (http://s252.photobucket.com/user/wvxvxvxvw/media/Bike/P1010048.jpg.html)

More to come tonight or tomorrow. I've still got to clear the frame before I start reassembly.

Title: Re: 86 Savage Restoration
Post by Tempted on 12/28/13 at 20:41:54

Okay I apologize for being WAY behind with progress/updates. I've been very busy with the hydrogen generator and haven't finished the Savage yet. I just bought a Honda Magna 750 with a dual disc front end that I'll be swapping onto the Savage.

Before being clear coated.
http://i252.photobucket.com/albums/hh15/wvxvxvxvw/Bike/P1010053.jpg (http://s252.photobucket.com/user/wvxvxvxvw/media/Bike/P1010053.jpg.html)
http://i252.photobucket.com/albums/hh15/wvxvxvxvw/Bike/P1010052.jpg (http://s252.photobucket.com/user/wvxvxvxvw/media/Bike/P1010052.jpg.html)

The starter still needs to be cleared.
http://i252.photobucket.com/albums/hh15/wvxvxvxvw/Bike/P1010064.jpg (http://s252.photobucket.com/user/wvxvxvxvw/media/Bike/P1010064.jpg.html)
http://i252.photobucket.com/albums/hh15/wvxvxvxvw/Bike/P1010063.jpg (http://s252.photobucket.com/user/wvxvxvxvw/media/Bike/P1010063.jpg.html)

The shock tops still have to be cleared.
http://i252.photobucket.com/albums/hh15/wvxvxvxvw/Bike/P1010066.jpg (http://s252.photobucket.com/user/wvxvxvxvw/media/Bike/P1010066.jpg.html)

The motor is getting set back in the frame in the morning. More pictures to come.

Title: Re: 86 Savage Restoration
Post by S-P on 12/28/13 at 21:10:45

Looking awesome!

Title: Re: 86 Savage Restoration
Post by Tempted on 12/29/13 at 12:41:58

This morning.

http://i252.photobucket.com/albums/hh15/wvxvxvxvw/Bike/P1010070.jpg (http://s252.photobucket.com/user/wvxvxvxvw/media/Bike/P1010070.jpg.html)
http://i252.photobucket.com/albums/hh15/wvxvxvxvw/Bike/P1010069.jpg (http://s252.photobucket.com/user/wvxvxvxvw/media/Bike/P1010069.jpg.html)
http://i252.photobucket.com/albums/hh15/wvxvxvxvw/Bike/P1010071.jpg (http://s252.photobucket.com/user/wvxvxvxvw/media/Bike/P1010071.jpg.html)

More pictures to follow as the parts are being re-installed.

Title: Re: 86 Savage Restoration
Post by HondaLavis on 12/30/13 at 08:42:19

That paint job looks SWEET! Can't wait to see your finished work!

You're going through the effort to make sure the bike looks great, but have you gone through the engine internally? I think someone else already said it, but it would be worthwhile to look at the camchain tensioner. I'd probably pry off the head cover and have a peak, too, but I'm known for finding issues before they become problems.

Or is that creating problems where there aren't any? :-?

Title: Re: 86 Savage Restoration
Post by justin_o_guy2 on 12/30/13 at 10:16:03

43727A67637273170 wrote:

[quote author=617E787F62655464546C7E72390B0 link=1386479491/15#19 date=1386879525]Ive got some raw metal that needs paint. Its not gonna be above 50* out there. The rattlecan says not to use it below 60.. What happens if I do?

It will likely run, won't stick well and won't dry for a very very long time. I use low temp activator and reducer when its cold out. I also just purchased a big kerosene heater for the garage. [/quote]

MMkay,, heres what I did. I fired up heaters & used a heat gun on places the heater wasnt hitting, heated up the rattlecan in front of the "Jet engine" kerosene heater. Primed, waited, heat it up some, waited, did the heat cycle a few times, then did the same with the red paint. Yes, it took a long time to dry. I still have no idea how the adhesion worked out, since Ive been careful with it. As for running, meeh,, I did no worse than any other paint work. If you looked at the generator propane mod job, you saw my handiwork with a rattlecan.

Thats a very nice shade of blue youre using. The starter & other little parts painted to match will make it really catch the eye. Im not much for flames & Im not at all into skulls & such, but that paint youve chosen would really support a silver "ice" detail of some sort. I hope Im using the right word. What Im trying to describe, Ive seen on Counting Cars.
They fixed up a Chevy ( wanna say about a 35 model) & boat painted to match. The silver flames were almost see thru, they were subtle, not "in your face", they highlited the base color, instead of contrasting or competing with it,
Of course, if ALL you do is paint it & do a fine job, that Color? Its gonna be so good lookin, the shocks, the starter, the detail, its gonna be a head turner.
Are you planning on smoothing out anything on the frame? Taking off reflectors, plugging holes, stuff like that?

Any changes planned for the chrome braces on the rear fender?

Title: Re: 86 Savage Restoration
Post by Tempted on 12/30/13 at 10:39:34

The reflectors are gone, most of the chrome is now matte black and I'm building some custom side covers, battery tray, head cover and rear light mount. Since I'm building the bike for my brother-in-law I won't be doing much custom work that I'd normally do on one of my personal bikes.

The internals looked great, there was light wear on the cam but the tensioner looked good. The piston was in great shape, compression is high and the cam "bearings" were perfect. There was a 1mm ridge that didn't bother me so I didn't ream it.

Title: Re: 86 Savage Restoration
Post by Tempted on 12/30/13 at 10:52:42

http://i252.photobucket.com/albums/hh15/wvxvxvxvw/Bike/P1010073.jpg (http://s252.photobucket.com/user/wvxvxvxvw/media/Bike/P1010073.jpg.html)

http://i252.photobucket.com/albums/hh15/wvxvxvxvw/Bike/P1010068.jpg (http://s252.photobucket.com/user/wvxvxvxvw/media/Bike/P1010068.jpg.html)

Title: Re: 86 Savage Restoration
Post by axa on 12/30/13 at 11:13:35

how are you finding your paint adhering to the aluminum?
if well, how are u prepping the aluminum?

Title: Re: 86 Savage Restoration
Post by Tempted on 12/30/13 at 12:31:15

DA sander, 80 grit, self etching primer, DA sander, 180 grit, automotive primer, DA sander 220 grit, automotive primer. Any of the chrome plated stuff has a copper coating below the chrome. When you sand the chrome off you find it. It won't have sticking issues.

I never have adhesion issues. I also anodize but won't be doing any on this bike. Its very hard to get a good match to paint when anodizing. Most black anodizing turns purple after a while and there is zero chance of me matching the Viper blue with a dye. Chances are this bike will never see inclement weather, extended high speeds or aggressive riding.

Title: Re: 86 Savage Restoration
Post by Tempted on 01/05/14 at 14:14:23

More excuses for not updating. I've been very sick and my sister(the one married to the man I'm building the bike with) lost a baby(pregnant with twins). I'll update in the next day or two.

Title: Re: 86 Savage Restoration
Post by justin_o_guy2 on 01/06/14 at 03:25:10

My wife works at a hospital, she says the place is full.

Title: Re: 86 Savage Restoration
Post by Tempted on 01/06/14 at 14:05:07

Even with the kerosene heater its too cold to work in the garage.

http://i252.photobucket.com/albums/hh15/wvxvxvxvw/Bike/P1010076.jpg (http://s252.photobucket.com/user/wvxvxvxvw/media/Bike/P1010076.jpg.html)

Title: Re: 86 Savage Restoration
Post by Tempted on 01/07/14 at 12:58:52

I didn't mention that all of the engine covers and mounts are painted with high heat(1700 degree) primer and enamel. I shouldn't have any issues with it.

Title: Re: 86 Savage Restoration
Post by Tempted on 02/04/14 at 17:34:30

I've made little progress on the Savage in the last couple of weeks. I picked up a couple new bikes, one being a 1980 Suzuki GS850 and the other a Honda Magna V65. Both are going to be rebuilt(neither were operational when I got them, the GS850 is now road ready and waiting on paint).

Since I had to rewire the entire bike I was checking that all the electronics were operational when I hit the horn for the first time. What I got was a startling duck call that made my dogs run in terror and me almost crap my pants.

[media]http://www.youtube.com/watch?v=Rzbf7Szgu44[/media]