Thumper Club Forum
Technical => Project Progress => Topic started by: guest288 on June 25, 2008, 11:41:25 AM
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Now I know how to post pictures, I thought I'd show how I'm getting on with the XBR rebuild.
First, the powder coated frame: :)
(http://i300.photobucket.com/albums/nn27/xbr500/IMG_1854.jpg)
The fork legs. I still can't seperate these... >:(
(http://i300.photobucket.com/albums/nn27/xbr500/IMG_1855.jpg)
I'll post some more when I've progressed a bit further...
Ta Ta
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Hummmmmm - poor joke and possibly child unfriendly alert.
Poor joke below.....
First pic suggests a fetish for bondage and in the second you cannot get the legs apart - is there a theme here, do you wish to discuss this amongst friends?
:)
R
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If your struggling to undo the slider retaining bolt that threads up into the fork leg from the spindle clamp, I've found a cheap alternative to the custom tool Honda want you to buy is a wooden broom handle. Stuff it down the fork leg with a bit of gusto and hopefully it will offer enough grip to the nut end for you to undo the bolt. Best of luck.
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Alternatively stick the chisel end of a wrecking bar down with the fork compressed and engage with the top of the damper rod, then use a good quality 3/8 drive allen key onto the allen bolt in the base. Works on Marzzochi' every time. If really bad, try an electric impact drill or air gun to spin it off. All the best.
My regards, Bill.
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I've managed to undo the bottom bolt up inside the fork leg, but I still can't seperate the leg from the tube... >:(
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Semtex?
R
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Hi, is there a circlip inside the top of the leg? I struggled for ages with a KX500 rear shock until I found one hidden amongst the crud(that will teach me about not cleaning things up properly!)
Jez
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Apparently not. The workshop manual says to slide the tube out sharply: the bushing thereon will drive the bushing and seal out of the slider.
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Hi, in that case put the fork leg in a vice,with something to protect the chrome, apply heat to the area around the bushing and push the slider up as far as it will go and then yank it as hard as possible, rather like a slide hammer. Had a similar problem with some Commando forks and this method worked on them.
Cheers Jez
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There's no circlip but there is a sprung wire clip thing jobbie behind the dust seal.
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I'll give it a go- I was a bit wary about how much to bash them about, but it sounds like I can give them a fair old crack. Will let you know how I get on...
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Woohoo! ;D
Got the fork legs apart, ordered some seals from David Silver so should be able to get the forks finished as soon as they arrive.
Stripped the Hagon shox I got from Steve, so when the DS stuff arrives should be able to bolt in the swingarm too.
Currently cutting alloy plates too blank off the engine ports prior to getting the whole lot blasted- any particular blasting process I should ask about???
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Aye Dave,
Are you leaving the lump whole?
Or are you going to put castings through? By the reading you are intent on the first rather than the second. However, if you are doing the second, see this thread from the site: http://www.thumperclub.com/smf/index.php?topic=2522.0
I have to say I'd be nervous of abrasive nasties getting in the lump, if you are proposing to do it whole ???
My regards, Bill.
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Hi Bill
I know that the engine was running well so I am a bit reluctant to split it, was rather hoping to put it through as a whole lump. Have heard things about soda blasting, anyone else know of this? Is there a better way of me scrubbing up the engine?? ???
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Aye Dave,
If you are sure you can seal all the orifices ??? I'd scrub it up with a stiff nylon washing up brush and a diesel/parrafin mix (50:50), then leave to soak. Give it another good scrubbing with more mix and leave to soak again. Now get a hold of Orange Jizer handcleanser with the polybeads in it or similar and give it a good scrubbing all over, then repeat and rinse with warm/hot water. Give it another wash with warm car shampoo and thorough rinse. Now you can Solvol what you want or just apply whatever cream/polish or else ACF50/Scotoiler365/WD40 protectant you prefer.
Regards, Bill.
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There's a coating called Nyalic (look it up in Google) that's used on spacecraft, aluminium boats used in saltwater, alloy window frames etc. It's pricey, but if you're happy to spend up large on powdercoating and blasting, that shouldn't bother you. It's way cheaper than doing it all over again next year.
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OK Guys, so this is what I'm dealing with:
(http://i300.photobucket.com/albums/nn27/xbr500/EngineRight-1.jpg)
(http://i300.photobucket.com/albums/nn27/xbr500/Enginebottomleft.jpg)
(http://i300.photobucket.com/albums/nn27/xbr500/Enginestartermotor.jpg)
If anyone can add any other ideas for cleaning this up then I'd be grateful.
:)
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Hi Dave,
You've got quite a job on your hands there!
To clean up the cylinder head cooling fins I got one of those small battery / hobbycraft drills from Lidl for £15 and it did quite a good job of getting rid of the muck and getting back to the metal. As for the engine side casings - I'd try rubbing them down and spraying with silver paint. David Silver has the casings for sale but that would get quite expensive (around £65 for both side, not counting the Starter Cover and Oil Filter casing). Good luck.
Let us know how you get on.
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Cheers CH,
I've had a go with a dremmel but it seems to go through brushes like no tomorrow-plus in one bit it seemed to get back to bare metal a bit too much.
I'm thinking along the lines of soda blasting- take it as one whole lump and get the casings done too- if I can find someone local, as lugging the engine about knackers you out somewhat...
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OK, so not much done until recently. Hope the pics come out ok...
(http://i300.photobucket.com/albums/nn27/xbr500/Frontview10-03-09.jpg)
(http://i300.photobucket.com/albums/nn27/xbr500/Forks10-03-09.jpg)
(http://i300.photobucket.com/albums/nn27/xbr500/Clip-ons10-03-09.jpg)
Yeah I know its slow, but hopefully I'll get it done by July... ;)
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It's looking splendid . Keep up the good work . These things take time to do properly .
Well done !
Rob .
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Good work mate,more pics soon,no pressure or anything..... ;)
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Ok, had a bit more of a go this weekend- not quite on Hurley's pace, but its coming along...
(http://i300.photobucket.com/albums/nn27/xbr500/Footpeghanger19-04-09.jpg)
(http://i300.photobucket.com/albums/nn27/xbr500/Frontsideview19-04-09.jpg)
(http://i300.photobucket.com/albums/nn27/xbr500/Mudguard19-04-09.jpg)
(http://i300.photobucket.com/albums/nn27/xbr500/Rearsideview19-04-09.jpg)
(http://i300.photobucket.com/albums/nn27/xbr500/Rearend19-04-09-1.jpg)
Regards all, Dave ;)
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Hang on, I just need to get my sunglasses :)
Very nice, very shiny
GC
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Love the orange - what colour is it?
R
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Yeah , ditto ,super colour, Dave . 8)
Can't wait to see the full job . Go to it !
Rob .
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Believe it or not, its the standard metallic red- I have those office lights in the garage, probably altering the colour a bit...
I'm going to leave the bodywork I think- I like the idea with all those shiny bits the bike can also show some of its history and battle scars!
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OK, a bit more done.
I've had a bit more time to spend on it so it's starting to come along.
(http://i300.photobucket.com/albums/nn27/xbr500/Frontwheelonbike.jpg)
(http://i300.photobucket.com/albums/nn27/xbr500/Rearwheelonbike.jpg)
(http://i300.photobucket.com/albums/nn27/xbr500/Calipermounted.jpg)
(http://i300.photobucket.com/albums/nn27/xbr500/OiltankFitted.jpg)
(http://i300.photobucket.com/albums/nn27/xbr500/Installingtheloom.jpg)
Just need to sort out the handlebar controls, and clean up the engine and that should be her ready to go!
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thats looking nice & clean, i hope mine turns out half as well
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Ok, managed a bit more time on the bike today- nothing major, just a few bits and pieces that seem to take time. More pics soon.
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That is looking good!- is that alloy polishing elbow grease or machine enhanced?
Mr Perfectionist says "are you getting those fork top header bolts rechromed? About £10 from www.qualitychrome.co.uk (http://www.qualitychrome.co.uk)
Are you sure that orange is red?
Cheers
John
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Hi John
The alloy stuff has been stripped where necesary with Nitromors paint stripper, then sanded with rough and fine grades of wire wool, then polished on one of those DIY polishing kits you stick in a drill.
I have brand new top nuts waiting to go in.
The colour is the metallic burgundy that loads of these were painted, my garage lighting just makes it appear more orange in the photos.
Regards
Dave
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Ey up Dave-
What polishing diy kits are those? I use the wet n dry to wire wool with brasso/ T-cut followed by a washing up scouring pad (knicked off the Mrs)- followed by a pair of pants with Autosol on them.......
followed by a clean pair of pants to polish them off....always leaves smeary brown skid marks though..... maybe i'll get SWMBO to change the powder....
The maroon paint jobby is called Honda Muse Red if yours is the maroon Burgundy-
Where did you get the top bolts from? Honda?
Cheers- John
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Hi John
The DIY polishing kit I've got comprises of three 4 inch mops and three types of compound, and an adaptor for fitting to a drill chuck- I got it from eBay for about a tenner.
Thanks for the paint name- I may need that if I decide to get the bodywork touched up a bit. I got the top nuts from David Silver- they weren't advertised on the website, but I've found if you ask, they can often order them in for you.
Regards
Dave
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Dave- no probs, the paint code is R-104C-U I know C means Candy- thats's it!
Were the top bolts cheaper than a rechrome?
If you need any xbr bits to complete give us a shout
Cheers
John
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Thanks John, I've started with a complete bike so I think I have everything there abouts, I'll let you know.
I think the top nuts were about £16 so a bit more than a re-chrome.
TurkeyUK is going to vapour blast my engine for me, I'll have a think and let you know if there's anything I need.
Thanks
Dave
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As promised, a few more photos...
(http://i300.photobucket.com/albums/nn27/xbr500/HandlebarLH.jpg)
(http://i300.photobucket.com/albums/nn27/xbr500/HandlebarRH.jpg)
The handlebar controls have been rebuilt, and the lever bits used to be black, just need chrome levers now! :D
(http://i300.photobucket.com/albums/nn27/xbr500/ThrottleCables.jpg)
Ends of the throttle cables polished up ok.
More pics when I get a bit more time to spend on the bike! ;)
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Blimey, wouldn't want to keep that lot clean ;)
Looking good
GC
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I'm gonna buy shares in ACF50..... ;)
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Bloody Hell- that polishing kit has had some hammer!
Can't you just polish the alloy black clutch/ brake levers?
Cheers
John
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Blimey, wouldn't want to keep that lot clean ;)
Looking good
GC
You wouldn't ;D
Mind at least you would get to ride it - more than I manage
R