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Discussion Starter #102
A real cause for concern was the clearance in the oven (touching the fresh powder or rubbing it against the oven is an automatic do over) and my gut instinct didn't fail me as I had do do 1 retake which added a good hour or more.... Doh





Try #2, there's some orange peel that I'm hoping will buff out and my body lead work is not as good as I thought. But all in all I think this may do.







Badge is goin to get reprinted but couldn't resist





Next the decals will get mounted then off to a body shop for clear coat.





As a side note while I was putting this post together I could hear a rucks at the neighbours, shooing something away, next our cat came tearing past me and I looked up to see this guy.... wanting in the garage for a feast of garbage.
 

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Discussion Starter #103
The hard way.....I just spent 4-6 hours sanding with 1200-2000 wet dry then cut polishing with a medium and a ultra fine, got a nice finish but a few blemishes made me toss it into the powder stripper :eek1


Here's the small area I tested, first with the 2000 paper



Then 2 steps of cutting compound





The light reflection says it all. I'm pleased with the finish and the clear should really make it pop but if I don't get what I want this time it's off to a body shop for wet paint
 

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Discussion Starter #104 (Edited)
I have a bunch of spare time and thought I get back in the build, maybe I can be ridding the CL this season. So far I have reread my old threads to find out where the hell I am and got some nice surprises along the way. Spent some time trying to revive the pics missing on page 1 but that’s not going to happen any time soon.

Monday I rescued this carb from the bucket of dead bugs and dust to get it ready for rebuild, it has been previously soaked in Pinesol ....I’d like it to shine more but I don’t want to spend a day polishing....(This is going to be a rider not a polisher) any quick and dirty ways to get rid of some oxidation?


305303
 

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Discussion Starter #105
Yesterday netted me a cleaned up and rebuilt carb, was nice to find I had already bought the rebuilt kits. For cleaning them up, used Scotch- Bright pad followed by some Autosol, they will need a little more cleanup that I will do during assembly.... good enough for a rider
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Now to deal with this nasty piece of business, right now it’s been soaking in Pinesol for 24 hrs and I think it’s time to find something else to do for a day or 2.
305306
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Discussion Starter #106 (Edited)
This can’t be good, while seeing what 24 hrs did to the float bowl revealed a hole in it, it’s sitting on a flashlight so you can see the light coming through, anyone have a spare carb or float bowl for one of these kicking around?
305309
 

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Discussion Starter #107
And today I thought I’d try placing the gunked up float bowl in CLR as it has a couple holes so there’s nothing to loose. It was a pleasant surprise that after about an hour (or 2) I was able to use an old toothbrush and the scale was gone, it worked so well I tossed the carb in and got decent results. There’s still some cleanup work but I just may be able to save this carb.
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PM me, I may be able to help on your carby by issues.
 

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Discussion Starter #109
Sooo... I started this 10 years ago and frankly I was a little intimidated by the torsion bar head and just put it off until I found a great head reassembly video. Perfect I though so after a little more research I pulled the head out from the cupboard drawer with a new found confidence only to realize I had already assembled it..... sheesh
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Today the head went on and now it’s down to another dreaded task, the timing chain. Hopefully that will get finished off tomorrow so I can finish assembly. As the project sits today I figure I’m about 80% to 90% complete and should be on the road this spring. Unless I get distracted again
 

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Discussion Starter #110
Today was a good day, I got done all that I was so concerned about. Started off by securing the bottom end at tdc and fixed the timing chain to the cam on the exhaust side
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Next was to hold that loaded intake cam into place and snake the cam chain to the front, secure the 2 ends then get the master link in place. This would be a great time to have 3 hands... I don’t know how they did it at the factory but they would have been bankrupt if I was the guy setting these up
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That’s as far as I can go today unti I can borrow a friends cam chain tool..... but it’s sure nice to have this part behind me
 

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The reason it was so challenging is because you're supposed to connect the chain on the intake side. The exhaust cam will sit where you put it, so you thread the chain over to the intake side after aligning the exhaust cam mark and then lever the intake cam to position, then slip the master link in the chain. That way you can actually do it with only 2 hands.
 

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Discussion Starter #112
The reason it was so challenging is because you're supposed to connect the chain on the intake side. The exhaust cam will sit where you put it, so you thread the chain over to the intake side after aligning the exhaust cam mark and then lever the intake cam to position, then slip the master link in the chain. That way you can actually do it with only 2 hands.
Now that just makes a lot of sense, it’s like me to find the hard way.
 

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Discussion Starter #113
Well that didn’t go well.... as I’m finishing off the head I notice this roller and shaft in a box

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further investigation reveals it should have gone in the cases before the cylinders are put on the pistons. Also noticed it was in poor condition so I ordered a new roller and I was never happy with the EK timing chain so I have a good DiD coming.

Im not going to touch the motor until the parts are here so I’ve moved on to the fussy, piddldy stuff... like powder coating the switches. Amazing how much time goes into this little stuff


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Discussion Starter #114
That was a decent days work, switches got reworked inside and out, Got rid of the rust, polished contacts and reassembled with dielectric grease. Took time to paint the lettering and it made sense to repaint the scabby side cover emblems while I had the paint out.

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Discussion Starter #115
From long term storage with a ton of dust it emerges for a wash down and it can go on the lift and get final reassembly, too bad the photo doesn’t show just how thick the layer of dust was.
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Make me wonder how I could have abandoned this project for so long being this close to completion.
 

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Very nice! I like the long term overhead storage solution, cheap and simple!

Sent from my Pixel 3 using Tapatalk
 

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Discussion Starter #117 (Edited)
While waiting for parts I took the time to learn how to nickel plate for all the bigger nuts and bolts, here’s the stock galvanizing vs nickel




Some parts are trickling in but nothing to exciting, my new DiD cam chain arrived from Germany before my stuff coming out of the US.




And it gave me time to clean up the clocks and a few other smaller items

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Discussion Starter #119
Love the plating! Need to learn how to do that and get setup myself!!
It is extremely easy, there’s tons of YouTube videos.... I’m using salted vinegar for my liquid and an old phone charger as a power supply. The nickel anodes can be bought on Amazon, the results seem to be good.
 

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It is extremely easy, there’s tons of YouTube videos.... I’m using salted vinegar for my liquid and an old phone charger as a power supply. The nickel anodes can be bought on Amazon, the results seem to be good.
Very cool, thanks!

Sent from my Pixel 3 using Tapatalk
 
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