SuzukiSavage.com - Project Bonnie Blue: Phase 1,2 & 3 (new pics)

Badass94Cad Senior Member Offline This space for rent Posts: 313 Mass-->Jerz-->PA! Gender:	Re: Project Bonnie Blue: Phase 1 & 2 Reply #15 - 07/13/12 at 05:13:39 The anticipation is killing me! Real good build pics so far.
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Cavi Mike

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Re: Project Bonnie Blue: Phase 1
Reply #16 - 07/13/12 at 09:05:44

justin_o_guy2 wrote on 07/11/12 at 21:48:45:

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,

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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splash07 Serious Thumper Offline Posts: 911 Charleston, SC Gender:	Re: Project Bonnie Blue: Phase 1 Reply #17 - 07/13/12 at 14:13:29 verslagen1 wrote on 07/11/12 at 21:08:35: carefull getting it thru the door, wouldn't want you to chip the paint. looks like building a ship in a bottle. I guess you will just have to stick around til the end to find out Captain Marvel...........Awaaaaaaaaaaay!!!!!!!!!!!!
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splash07

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Re: Project Bonnie Blue: Phase 1 & 2
Reply #18 - 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.

You can see there where the rotor spokes were rubbing. Undecided

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.

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.

Im already working on repainting it.

New pads were in order as well.

New v. old

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« Last Edit: 02/20/20 at 08:48:29 by splash07 »

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splash07

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Re: Project Bonnie Blue: Phase 1 & 2
Reply #19 - 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.

I cut about 6 slots in the neck too.

Here is the header all wrapped in fiberglass, its main purpose is to protect my boots, since I removed those heavy heat shields.

All put together:

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« Last Edit: 02/20/20 at 09:37:39 by splash07 »

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splash07 Serious Thumper Offline Posts: 911 Charleston, SC Gender:	Re: Project Bonnie Blue: Phase 1 & 2 Reply #20 - 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. Time to clean it up and get it ready:
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splash07

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Re: Project Bonnie Blue: Phase 1 & 2
Reply #21 - 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 Roll Eyes

Maybe a set of these:

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.

and of course I only use the best parts and supplies:

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.

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. Cheesy

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« Last Edit: 02/20/20 at 08:38:36 by splash07 »

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splash07

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Re: Project Bonnie Blue: Phase 1 & 2 & 3
Reply #22 - 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.

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!!!

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« Last Edit: 02/20/20 at 08:35:41 by splash07 »

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splash07

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Re: Project Bonnie Blue: Phase 1 & 2 & 3
Reply #23 - 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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« Last Edit: 07/15/12 at 11:14:19 by splash07 »

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Badass94Cad Senior Member Offline This space for rent Posts: 313 Mass-->Jerz-->PA! Gender:	Re: Project Bonnie Blue: Phase 1,2 & 3 Reply #24 - 07/14/12 at 15:58:35 Awesome build pics. Great thread.
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ToesNose Serious Thumper Offline Pardon me, do you have Hot Sauce? Posts: 1993 Mooresville, NC Gender:	Re: Project Bonnie Blue: Phase 1,2 & 3 Reply #25 - 07/14/12 at 17:19:01 Sweet ride Splash, thanks for sharing your build
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Borracho Full Member Offline SuzukiSavage.com Rocks! Posts: 132 Albuquerque, NM Gender:	Re: Project Bonnie Blue: Phase 1,2 & 3 Reply #26 - 07/15/12 at 16:19:07 Sweet ride, you should be proud. I especially like the paint.
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mojohand40 Junior Member Offline SuzukiSavage.com Rocks! Posts: 80	Re: Project Bonnie Blue: Phase 1,2 & 3 Reply #27 - 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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splash07

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Re: Project Bonnie Blue: Phase 1,2 & 3 (update
Reply #28 - 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!

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« Last Edit: 02/20/20 at 08:26:02 by splash07 »

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Kilgore Trout YaBB Newbies Offline Posts: 19 Columbus, Ohio Gender:	Re: Project Bonnie Blue: Phase 1,2 & 3 (new pics) Reply #29 - 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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