Woo Hoo! A Big Project!

Discuss all things 1970 & later Airheads right here
Post Reply
User avatar
melville
Posts: 1402
Joined: Tue Aug 03, 2010 8:32 am

Woo Hoo! A Big Project!

Post by melville » Fri Aug 13, 2010 9:41 am

Some of you might remember this:

http://boxerworks.com/phorum5/read.php?3,36224

Which appears to be in flat view for everyone now, so it's a bit easier to read the later posts but kinda hard to check the context. I'll give a Cliff's Notes version of what's there, and resume the fun where I left off.

For my 40th birthday Mrs. melville bought me this:

Image

I was flabbergasted. It was a total surprise. She knew I'd always wanted a bike but would never get one myself. She's not stupid--note that it has no carbs mounted. They were in a box in a zillion pieces. She also had me sign a contract that it would get a full, to the bare frame and back up again, restoration, before I became a regular rider. So cut to 2 1/2 years (2 VW motors and a shoulder surgery) later and things looked like this:

Image

I made it run and rode it around the neighborhood a bit evaluating the motor and trans as best I could, and then I started on satisfying the terms of the contract.
Call me Mel. Some years ago- never mind how long precisely- having little or no money in my purse, and nothing particular to interest me at home, I thought I would ride about a little and see the other parts of the world.

User avatar
melville
Posts: 1402
Joined: Tue Aug 03, 2010 8:32 am

Re: Woo Hoo! A Big Project!

Post by melville » Fri Aug 13, 2010 9:54 am

General condition of things before disassembly--Frame was within 1/32" of straight using Duane's String Test:

Image

Image

Motor was crusty and leaky:

Image

Image

With barbacks like these removing the tank was a bear:

Image

So things got to be like this:

Image

The motor had lousy compression on the left side when I first got it going. Compression came right up to spec in a few miles and I was tempted to leave the motor alone, but more of that anon. Trans was classically clunky, but I myself was clunkier. Clutch made a big "Squartch" sound when starting from rest. Bike had a low frequency weave, possibly due to tight head bearings. Never felt a wobble.
Call me Mel. Some years ago- never mind how long precisely- having little or no money in my purse, and nothing particular to interest me at home, I thought I would ride about a little and see the other parts of the world.

User avatar
melville
Posts: 1402
Joined: Tue Aug 03, 2010 8:32 am

Re: Woo Hoo! A Big Project!

Post by melville » Fri Aug 13, 2010 9:58 am

And then it came apart:

Image

Image

Image

Image

Image

Image

Image
Call me Mel. Some years ago- never mind how long precisely- having little or no money in my purse, and nothing particular to interest me at home, I thought I would ride about a little and see the other parts of the world.

User avatar
SteveD
Posts: 4174
Joined: Tue Aug 03, 2010 3:29 am
Location: Melbourne, Oz.

Re: Woo Hoo! A Big Project!

Post by SteveD » Fri Aug 13, 2010 10:12 am

I'm predicting 150+ posts.
Go Melville go! This new board needs a rebuild thread!
Cheers, Steve
Victoria, S.E.Oz.


1982 R100RSR100RS supergallery. https://boxerboy81.smugmug.com/
2006 K1200R.

User avatar
melville
Posts: 1402
Joined: Tue Aug 03, 2010 8:32 am

Re: Woo Hoo! A Big Project!

Post by melville » Fri Aug 13, 2010 10:24 am

Things found in disassembly. Just a little water in the trans oil:

Image

But not in the drveshaft or final drive. Another issue there, however. I checked the fill plug on the drive shaft first and it came right out, as did all other plugs, but for the driveshaft drain plug, which did this:

Image

My local airhead guy is fixing that now and replacing the seals. No metal chunks in any of the oils, and just a sheen in what I pulled off the FD drain plug.

Found the rumble:

Image

Getting new bearings all around, wheels, swingarm, head.

Odd electrical stuff here and there--no evidence of a trailer or lit bags:

Image

Dual filament bulbs in the rear turnsignals for running light function. A few soldered connections:

Image

More soldered connections in the headlight bucket for the fairing harness. A little disappointing as it would have been easy enough to connect directly to the junction board:

Image

Bike is to go back together naked and stockish, so some repair was necessary to the harness.

Coupla cracks in the frame. NBD--welded back solid by my local airhead guy:

Image

Image

Splines look good all around:

Image

Image

Image

Battery mounts had perished:

Image

PO didn't like oil vapor in the airbox, so he extended the breather hose through a hole in the filter. No great accumulation of oil on top of the trans or in the clamshell, thankfully:

Image

Image

More to come.
Call me Mel. Some years ago- never mind how long precisely- having little or no money in my purse, and nothing particular to interest me at home, I thought I would ride about a little and see the other parts of the world.

User avatar
gspd
Posts: 372
Joined: Tue Aug 03, 2010 8:04 pm

Is there a scheduled unveiling date yet?

Post by gspd » Fri Aug 13, 2010 7:32 pm

Almost finished?
I wanna see this sucker!
Image

Deleted User 61

Re: Woo Hoo! A Big Project!

Post by Deleted User 61 » Fri Aug 13, 2010 7:33 pm

Make sure Duane knows about the little orange button!

read this post, Duane!
http://boxerworks.com/forum/viewtopic.p ... t=30#p1022

User avatar
melville
Posts: 1402
Joined: Tue Aug 03, 2010 8:32 am

Re: Is there a scheduled unveiling date yet?

Post by melville » Sat Aug 14, 2010 9:47 am

gspd wrote:Almost finished?
I wanna see this sucker!
As some of it goes back together some of it is coming apart, as you'll see soon. Hoping for Labor Day. Our best weather here is September and October anyway.
Call me Mel. Some years ago- never mind how long precisely- having little or no money in my purse, and nothing particular to interest me at home, I thought I would ride about a little and see the other parts of the world.

User avatar
melville
Posts: 1402
Joined: Tue Aug 03, 2010 8:32 am

Re: Woo Hoo! A Big Project!

Post by melville » Sat Aug 14, 2010 10:02 am

Nice of you to chime in, gspd, as your guidance made the next section possible. On with the BLING fetish--here's my steering yoke as it came outta the bike:

Image

After one pass on the buffer (looks like dookie):

Image

gspd chimes in, says I must file off stuff and sand the bejeezus out of things to get THE LOOK:

Image

He might be right:

Image

He IS right:

Image

This leads to further adventures in BLING:

Image

Image

Image

Image

The caliper was a special case. I really just wanted to smooth out the tool marks and paint it:

Image

Image

Image

Image

But one thing led to another:

Image

I put a coat of paint on it after the above pic but it looked awful, so I sanded it off and went a few steps further (meanwhile, getting the levers and throttle cover):

Image

And a close-up:

Image
Call me Mel. Some years ago- never mind how long precisely- having little or no money in my purse, and nothing particular to interest me at home, I thought I would ride about a little and see the other parts of the world.

User avatar
melville
Posts: 1402
Joined: Tue Aug 03, 2010 8:32 am

Re: Woo Hoo! A Big Project!

Post by melville » Sat Aug 14, 2010 8:11 pm

So you may be asking, "Gosh, melville, whatcha gonna do with the crusty cast parts?" Well, I'll tell ya, I listened to gspd, professor of BLING, and I am NOT polishing them. They got cleaned up with #3 ScotchBrite or #3 steel wool as necessary and then got a heavy wash of silver spray paint applied with a softer ScotchBrite pad. Credit also to Chuey on this method. Here's where the front cover started:

Image

Here's the front cover after abrasives and paint, the clamshell parts are as found and post abrasive:

Image

And the motor itself magically fits my VW engine stand after a wee spot of filing on the mount. I had to degrease it with successive rounds of Simple Green and Brakleen, then worked it with ScotchBrite

Image

Here's how I got the cylinder fins. As it was:

Image

A little shoeshine:

Image

A different technique in the tight spots:

Image

And how it looks now, with some of the covers in place:

Image

Circumstances are such that the cylinders are coming off and will have the opportunity to get bead blasted. I am likely to paint them black, going for that R75s look.

Other cast bits--the disc carrier before:

Image

And after:

Image

More to come.
Call me Mel. Some years ago- never mind how long precisely- having little or no money in my purse, and nothing particular to interest me at home, I thought I would ride about a little and see the other parts of the world.

Post Reply