Congrats Waz, I know that feeling well. Good job, and that smoke is a welcome sight to see. Mine stopped smoking after I ran it round the paddock a few times.
RT

I have been inspired after seeing Mr Klompy's RS and Mr Smithy's RS last weekend, it will never be as good as them but it will do me. Replacing fork seals and cleaned up bottom legs today. New brake discs and braided lines tomorrow so plenty of swearing about the air in the top hose tomorrow afternoon.
 

some nice work there waz

the old girl is really taking shape

leaving them silver ?   and some polypropolene coating to protect them well ?

hope the rest of your goodies arrive and we get to see them fitted up ol mate ..

cheers

Thanks Charlie
I was going to ask what type of paint you suggested you saved me asking. Silver with polypropolene.

maybe polypropolene clear coat might be easier to find ....forgotten what the trade name for that stuff is  sorry mate ...just a silly old fella here .....at times

Thanks Mate
I will get some polypropolene clear coat tomorrow and act like I know what I'm talking about.

Hey great work Waz , it looks like you've got the fork lowers very clean. Now if I was painting them I would hit them with prepsol then give them a few coats of quantity 2K Clear (dulux ) with 2k hardener and reducer. If you do this make sure you have a quality mask and good ventilation.

KBS Coatings is the go Waz but as always it's expensive
http://www.kbs-coatings.com.au/

Finally I have front brakes. New discs, pads, braided lines and master cylinder kit. Ready for number plate from RT  to go on and finally ride around the block tomorrow.

Jack was overseeing and give the all clear to test ride.
 

Careful on the first run waz. I put new disks/pads on the R/RT before guyra and basically had no brakes for about 100Kms odd till they settled in. They advised 300Kms before hitting them hard. Of course they are really good now after that run around the tablelands

make sure you clean off the disks first waz

brake cleaner etc ?
some of them have a fine layer of oil after coming out of their wrapper (mine did )  and I would say would embed in the brake pads pretty quick ol mate

looking great ...

Great job Waz, you have waaaay too much time on your hands.
That bike is really starting to look great.

If you want to use a non-greasy/oil free brake cleaner then I would suggest white spirit. That's what we used on aircraft brakes and hydraulic components. It can burn your skin if not careful , so gloves and eye protection recommended. 

Cheers, Dave.

Got a couple of hours in the shed today. Washed oil from the new discs and fitted new rear disc, brake pads, braided line and master cylinder kit, all the brakes are sorted now. Onto oil / water pump. Have to finish it later mossies are getting me.

nice work mate, those headers are magnificent....
...need to revisit mine now...by the way will we see you in the morning for the run to Goulburn via Robertson etc?...will bring my gopro and camera....lets see if technology lets me down or supports me this time....

See ya tomorrow, my son wants to have a look too, I will be going slow, he just got an old Harley so I will have to wait for him. Luckily all the bits are shiny so they will be easy to find on the side of the road when they shake off.

Waz you should know better than post things like that on Berts nice respectable forum 

looks good waz
 

charlie99 wrote:looks good waz
 

Agreed. With a caveat - I'd re-route that rear brake line over the swingarm.

Yeh, I am not happy with the lenght of the braided line, I think I will remove the steel line from caliper and run the braided line all the way to caliper through a banjo bolt.

RicK G wrote:KBS Coatings is the go Waz but as always it's expensive
http://www.kbs-coatings.com.au/

coming along well there Waz,you're certainly catching up with the resto.
Rick , the KBS coatings are top stuff , especially if you are not familiar with 2 pak. 
Just be sure to hit your job with a primer first , as the KBS penetrates into metal and can only be removed by grinding.
It is a tough paint and doesn't chip, great for forks and frames.
that bike trolley certainly makes the job easier , best investment for the reno Waz.
definitely run the rear line over the top. looks good.
keep it up mate.

Waz you should know better than post things like that on Berts nice respectable forum

Karma got me, nothing fell off the sporty but I lost the cap of the rear brake resivour. Serves me right for mouthing off. Went back but couldn't find it, if it was shiny I may have had a chance.

Waz wrote:See ya tomorrow, my son wants to have a look too, I will be going slow, he just got an old Harley so I will have to wait for him. Luckily all the bits are shiny so they will be easy to find on the side of the road when they shake off.

Looks like your son got a good old sportster, he'll enjoy that .

He was enjoying it today over Macquarie pass, he was dragging his toes through every corner and I was so proud of him untill I remembered he was wearing my boots.

I have had Rosko's special recycling soda blaster going today. Works great but my compressor is too small. Next time I will take it all to work and use the large compressor on a Saturday.
 


The soda falls into the bottle and the pick up sends it around again. Very clever Rosko.

oil pick up had a restriction and hair in it.
Before

After

New sight glass fitted while sump was off, it was very easy to push out from inside.

Good work Waz, what are you going to use as a sealant for the sump when you put it back? and how did you get your bike upside down??

RT wrote: and how did you get your bike upside down??

All your bikes are upside down.

I'm just waiting for the paint to fully cure, then I'll be using Three-Bond when I re-fit the sump plate on this:

Hi Bob
I used Permatex on sump and water pump cover. I also put some on the oil pick up where it goes into the back of the pump. Has a new seal but I got carried away. Filled with oil and no leaks yet but it's early less then 24 hours. I welded one of your brackets yesterday will do the other one now.

Nice finish on the sump Mike

and how did you get your bike upside down??

Only Sean and I know.

Shiny black is good, you can't tell if there's a leak until it drips on your floor.

I have always used the Permatex gasket stuff ever since it came in a .... with a brush. It failed me on the rocker/ cam cover recently, should have got a new gasket, hard and end of life, but only in one spot which tells me my error not the goo.... maybe? Or just wrong on that rubber application ?

Needed a day of therapy today, I sold my KTM 520 so have to had to stay busy to keep my mind of selling my chook chaser.


After soda blasting then painting with clear. I was not happy so I soda blasted again to remove the clear and clean up better and painted with clear again but still not happy but I have put them back anyway.

Checked valve clearances and replaced thermostat and front seal in timing chain cover.

Looks better in photo than in life but I am gunna live with it I have to move on and do somthing else or I will never finish.

What are your clear coating them with Waz, rattle can acrylic?

looks good waz

pitty the clear coat kinda makes it a dull metal finish eh? ,,, washes out all the sparkle that we spend so much time achieving

Looks the goods to me mate, you must have too much spare time.

Thanks, I just used rattle can acrylic, after I make some porgress with the rest of it I will soda blast them again and leave bear origional, I like the origional look but wanted to clear coat to make cleaning easy.



Never enough time Bob, Next is rear seal bit I want to see how you and Rosko do it before I have a go.

Got the rear seal out

Have new one soaking in oil then into the freezer overnight to tap in tomorrow morning.

final drive and drive shaft splines are cabbage

still some k s left in it waz .....i said some



doing well mate !....keep at it

Thanks Charlie
After cleaning it all up I think the final drive is OK it still has square shoulders. Shaft is littile triangles. The final drive must be harder metal. I think I might get away with just the drive shaft.

I finally rode it for the first time today, my new water pump leaks coolant and I have a noise when moving, the faster I go the faster it ticks or knocks. It's not the motor because the knock increases with speed not revs. Blowing smoke like a steam train but no oil leaks yet. Feels good. Getting close now.

pretty common to not seal up the top of the waterpump front cover properly waz

its deceptive because it finds its way through the cable relief hole and drips from the bottom ....

good to hear its running and moving ...keep at it mate ....

cheers !

Thanks Charlie, that's what happened and the noise is a vibration in the back of the head light it was doing it stationary today in the shed and I felt around the back of the head light and it stopped. Silly little things now.

Hey Waz , black beauty's  really looking the part now, glad to see it's up and running mate.

Thanks Mate
It's done, I put good tyres from the LT on today so it just needs rego.
Thank you to everyone who helped with advise, encouragment and parts.

The knowledge and free advise here is incredible and with out this forum and help I received I never would have had the confidence to do it.
Tank started out like this.

The day I bought it


Today

It was pretty nice to start with, I wonder why it took so long and where did all the money go?

Ha Ha I think you mixed the photo's up mate. If I hadn't seen all the work you were doing I'd wonder where the money went as well.
For anyone who doesn't know, Waz is a really generous man with his time and equipment, don't mean to embarrass you Waz but thanks for your help.
RT

You have done a great job!  

It has inspired me to start my own rebuild post as my bike was in a shed for around 7 years.   I have enjoyed the help from this form so much just wished I had found it before I started.  

Happy and safe riding.

Well done Waz! Cant claimed to have helped in any way at all - but thanks for helping me!