tag:blogger.com,1999:blog-53874164353344816002024-02-20T15:15:19.627-05:00zebraskunkUnknownnoreply@blogger.comBlogger33125tag:blogger.com,1999:blog-5387416435334481600.post-49544251859977552922016-02-18T16:19:00.000-05:002016-02-18T16:19:19.722-05:00The Tail: Frame prep continues<div class="separator" style="clear: both; text-align: center;">
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Since I'm going to be ditching the stock licence plate bracket, turn signals, and grab bar, I've got a bit of clean up to do on the tail of the AR80's frame.<br />
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This is one of the passenger grab bar brackets.<br />
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And this is where the stock licence plate holder bolts on.<br />
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I finally have a chance to use one of my Christmas presents. A Bosch 4.5" angle grinder.<br />
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This should be just a bit faster than my Dremel tool with a cut off wheel.<br />
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Yep, I zipped these things off in no time.<br />
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Better.<br />
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I pulled the plastic bar ends out of the frame. I don't want to melt them when I cut off the licence plate bracket. I have a plan for them.<br />
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Nice.<br />
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Cutting off useless frame parts is almost as satisfying as deleting useless source code.<br />
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That is looking nice and tidy. But what about those bar ends?<br />
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My plan is to insert these Supernova LED turn signals (from Revival Cycles) into the frame using the stock bar ends.<br />
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They are just about the perfect size.<br />
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I'll drill a whole through the bar end, and then fish the wire through the frame.<br />
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Hole drilled.<br />
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Bar end LED turn signal constructed.<br />
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Make that a pair.<br />
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Then I drilled holes in the frame to fish the wires through.<br />
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It wasn't too hard. I stuck a piece of electric fence wire through first, taped the wire to it, and then pulled it back through.<br />
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Note: There is literally nothing electric fence wire can't do.<br />
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I didn't push the bar ends all the way in because they are kind of a pain to pull back out. I'll wait until final assembly to put them in for good. But this gives an idea of how it'll work.<br />
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I think they'll look pretty good once the frame is black and they are pushed all the way in.<br />
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The next things to eliminate are the forward grab handle bolt holes. I won't be using them, so they must go.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgbD8yEv25v996EJNTM5QyHE9XN3MY2N-12FhTO_xaLqQdAFNHH6FDuJ_9n8hYG6UkdfoB7GVoFQv_apyipOmW6_EbHILMzcswtSfl41n5yoQgDsJQ5dbf_Zb2g0HgnoRqjfLXEd6aIAOSr/s1600/IMG_6579.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgbD8yEv25v996EJNTM5QyHE9XN3MY2N-12FhTO_xaLqQdAFNHH6FDuJ_9n8hYG6UkdfoB7GVoFQv_apyipOmW6_EbHILMzcswtSfl41n5yoQgDsJQ5dbf_Zb2g0HgnoRqjfLXEd6aIAOSr/s640/IMG_6579.JPG" width="640" /></a></div>
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I am not a welder. But I did manage to fill the holes with metal using a welder.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbr8PzL-7rmfR3Q1BBk7rmOafXUYMJ4pS0auGJ0dO6WqgdIntEP7D2Wl4K9wm-CXM95prsl8rS-abomEw6tGwaDCfapvU3QOp9knWKbpc2Q-7KE__8-ujSNL0qxTmlpP6rC9xeP1L1kGNG/s1600/IMG_6581.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbr8PzL-7rmfR3Q1BBk7rmOafXUYMJ4pS0auGJ0dO6WqgdIntEP7D2Wl4K9wm-CXM95prsl8rS-abomEw6tGwaDCfapvU3QOp9knWKbpc2Q-7KE__8-ujSNL0qxTmlpP6rC9xeP1L1kGNG/s640/IMG_6581.JPG" width="640" /></a></div>
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But let me stress, I am not a welder.<br />
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A couple of weld and grind sessions later, the holes are gone. I welder would only need one session. I am not a welder.<br />
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The little divots that remain will disappear when powder coated. Not a welder.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi4aIvFSd95yAmEvO78G8z5xlvkLmt3jgyC9c4FU1KbNKKNlUEkMJrRpBW74Db2KpjnjgcPmCz9Er8NpaTe5iNv4yH-sTHLAd0akU7xxULGLI1TFxOHo6bowRxnJqiMli1pXT9o0jPcZsSC/s1600/IMG_6584.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi4aIvFSd95yAmEvO78G8z5xlvkLmt3jgyC9c4FU1KbNKKNlUEkMJrRpBW74Db2KpjnjgcPmCz9Er8NpaTe5iNv4yH-sTHLAd0akU7xxULGLI1TFxOHo6bowRxnJqiMli1pXT9o0jPcZsSC/s640/IMG_6584.JPG" width="640" /></a></div>
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Mommy and baby got home before I had a chance to finish grinding everything down smooth, but still, I am pretty happy with the progress. There are a few more things to take care of on the frame, but I am getting dangerously close to powder coating this thing.Unknownnoreply@blogger.com3tag:blogger.com,1999:blog-5387416435334481600.post-65418084533990608182015-08-23T22:50:00.000-04:002015-08-23T22:50:08.065-04:00Tail Plastic<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjE0BwAHl75xxCza7QpDfLqrNYdvF8GqfSOMWMR13SvcfDCr_Cy-O-FtnhWfFO5ucb_kWlh3BOxdWMmEHmq0atcOvW4MJAYdx_5ySzWOphzJaZyLqdZT0VVbAlA0ykE2TrPEas4gaS1IrWj/s1600/IMG_6040.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img alt="Stock Kawasaki AR80 tail plastic" border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjE0BwAHl75xxCza7QpDfLqrNYdvF8GqfSOMWMR13SvcfDCr_Cy-O-FtnhWfFO5ucb_kWlh3BOxdWMmEHmq0atcOvW4MJAYdx_5ySzWOphzJaZyLqdZT0VVbAlA0ykE2TrPEas4gaS1IrWj/s640/IMG_6040.JPG" title="" width="640" /></a></div>
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I plan on reusing the AR80's plastic tail piece, but it needed to be cleaned up and modified for my new tail light.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQkX3PD7L2eSJ0Qrhxpi6tXdW40msXJHA3OFDySz5WKSrKHN2XxHttNHwZU0E07z0_CwjGI6S_ZlTjQe_afxpTlf1hc1Exso2X14KVjAoq2SZV63EX2WjybWXdAgVp3o8u_vEEedCyeue9/s1600/IMG_6039.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img alt="Stock Kawasaki AR80 tail plastic" border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQkX3PD7L2eSJ0Qrhxpi6tXdW40msXJHA3OFDySz5WKSrKHN2XxHttNHwZU0E07z0_CwjGI6S_ZlTjQe_afxpTlf1hc1Exso2X14KVjAoq2SZV63EX2WjybWXdAgVp3o8u_vEEedCyeue9/s640/IMG_6039.JPG" title="" width="640" /></a></div>
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Overall the plastic was in good structural shape.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjLkTgH_K_aQNwa7NncCxDStslXB9xjXRptxH2sbbFQHI6IhVIS2dvjMizL_MTcY5lUV0nG4mdExVY7jJo8t6LTfx7QdCvlD2dobjf3mpek9bmiiC_MT_SSA5RHYAasBcDAUHeBAqHPivUH/s1600/IMG_6041.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img alt="Stock Kawasaki AR80 tail light mounting holes." border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjLkTgH_K_aQNwa7NncCxDStslXB9xjXRptxH2sbbFQHI6IhVIS2dvjMizL_MTcY5lUV0nG4mdExVY7jJo8t6LTfx7QdCvlD2dobjf3mpek9bmiiC_MT_SSA5RHYAasBcDAUHeBAqHPivUH/s640/IMG_6041.JPG" title="" width="640" /></a></div>
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Except for this hole. I don't think that was the stock hole for the stock tail light. I'm not sure why the PO mangled it so badly.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhDGptHtrRxmQVXL60_rw2RWC2eyL9DGLXCr5TflaEuXpZAJQZeFcJDQxPcDbpgoSh6OtC93uWwbPfx0-j6Vo1iFPFS4deqPvAdgsuM1ygEC408U3I3omQynNslKsvCbDv6MDygCw4HVC47/s1600/IMG_6042.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img alt="Stock Kawasaki AR80 tail light mounting holes." border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhDGptHtrRxmQVXL60_rw2RWC2eyL9DGLXCr5TflaEuXpZAJQZeFcJDQxPcDbpgoSh6OtC93uWwbPfx0-j6Vo1iFPFS4deqPvAdgsuM1ygEC408U3I3omQynNslKsvCbDv6MDygCw4HVC47/s640/IMG_6042.JPG" title="" width="640" /></a></div>
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No biggie. I planned on filling the stock mounting holes anyway because my taillight only needs a single small mounting hole.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhSDcpnVEWScRAKfIb47GEUDJ98af61VAUY2zAoq3ApHZc9hmcXfnH_ivs3vtbG0eLeVvDKtdEo2Z-YzEEHPX4r4j6PCiaY5rGGPkcbHYqE4HEwxyO8rVyEoL7WnLoSdnmd_1yOTxQuwx2r/s1600/IMG_6043.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img alt="JB KwikWeld Epoxy" border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhSDcpnVEWScRAKfIb47GEUDJ98af61VAUY2zAoq3ApHZc9hmcXfnH_ivs3vtbG0eLeVvDKtdEo2Z-YzEEHPX4r4j6PCiaY5rGGPkcbHYqE4HEwxyO8rVyEoL7WnLoSdnmd_1yOTxQuwx2r/s640/IMG_6043.JPG" title="" width="640" /></a></div>
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I bought some JB KwikWeld Epoxy to fill the old holes.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhZo-QLHGJcXTszmPNdtnpDOxseA1Gvj5BVMKuSnb_CM7giZNh710rF9hWhDc4RZCxQowoT8ELy4bhcG0aHMAo6uLFKd1MCssRtQr5ebekfPDCcf5_3lAKAHaIUXZV1wrnpjT3qGcvAvPeJ/s1600/IMG_6045.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img alt="Duct tape. What can't it do?" border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhZo-QLHGJcXTszmPNdtnpDOxseA1Gvj5BVMKuSnb_CM7giZNh710rF9hWhDc4RZCxQowoT8ELy4bhcG0aHMAo6uLFKd1MCssRtQr5ebekfPDCcf5_3lAKAHaIUXZV1wrnpjT3qGcvAvPeJ/s640/IMG_6045.JPG" title="" width="640" /></a></div>
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I put some duct tape over the old mounting holes.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiGwk191IS9zBV6_cjtfoHQ2_BMS6EnjxvpjE8lo6DbQTZXkYFjS9_NuNqfGzBn9nTHpiSNdU1km5_o6DDWzlfGz3VFAN6O3xf8j-Fc0x3M4YQNbMPo34o0SmqrtQ7wQgJsxSI_zpqkN9_P/s1600/IMG_6047.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img alt="Scuff it." border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiGwk191IS9zBV6_cjtfoHQ2_BMS6EnjxvpjE8lo6DbQTZXkYFjS9_NuNqfGzBn9nTHpiSNdU1km5_o6DDWzlfGz3VFAN6O3xf8j-Fc0x3M4YQNbMPo34o0SmqrtQ7wQgJsxSI_zpqkN9_P/s640/IMG_6047.JPG" title="" width="640" /></a></div>
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And scuffed up the inside plastic to give the epoxy something to hold on to.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEixvPJ8b873B4VqJmQU3m46OrjOclhFkoPy52-vkxTNA9aevE8MOtwG-WKEcQhthp91TK1C7sNhIe7dwvWJ6lRoKrHvOaWGW8SEB9X61yrhyphenhyphenx_cvJuzZ4z282BYLjRB76dycBj25Yox51Pi/s1600/IMG_6048.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img alt="Mmmmm. Generic cinnamon toast crunch." border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEixvPJ8b873B4VqJmQU3m46OrjOclhFkoPy52-vkxTNA9aevE8MOtwG-WKEcQhthp91TK1C7sNhIe7dwvWJ6lRoKrHvOaWGW8SEB9X61yrhyphenhyphenx_cvJuzZ4z282BYLjRB76dycBj25Yox51Pi/s640/IMG_6048.JPG" title="" width="640" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi-Q1ccds4cTlqF0HVQnpzuAeS4StNJtdY8NM-GNegcZPz9hQiRANwRTSsAPs94jvGi5rVWDwGoLRQpAk9AO9esNl_xTcZMf86yC1f4lo3JS9Br6IjnuA8rRD0VdSG-vlonxBGdY4JH0Cke/s1600/IMG_6049.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img alt="Delicious" border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi-Q1ccds4cTlqF0HVQnpzuAeS4StNJtdY8NM-GNegcZPz9hQiRANwRTSsAPs94jvGi5rVWDwGoLRQpAk9AO9esNl_xTcZMf86yC1f4lo3JS9Br6IjnuA8rRD0VdSG-vlonxBGdY4JH0Cke/s640/IMG_6049.JPG" title="" width="640" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhgtT91UW76CNBf3FHCh87HNxsLfmepxJ8Iqxw9pnl1Dzg4n_2ybmSEvFtPetgK2TdJ_j2RZTir8KigdsA03eruc9VNVANwVh8l3MsRzz6PhzQ_V2j2d9hAiMH7bFEejnXEyrGOmbFkk0MU/s1600/IMG_6050.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img alt="JB KwikWeld Epoxy" border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhgtT91UW76CNBf3FHCh87HNxsLfmepxJ8Iqxw9pnl1Dzg4n_2ybmSEvFtPetgK2TdJ_j2RZTir8KigdsA03eruc9VNVANwVh8l3MsRzz6PhzQ_V2j2d9hAiMH7bFEejnXEyrGOmbFkk0MU/s640/IMG_6050.JPG" title="" width="640" /></a></div>
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Once mixed I liberally slathered the epoxy over the old mounting holes. I don't really care what it looks like on the inside so I wasn't particularly careful.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjjBsLSGCj2HGunYsyf4lb5bIzoX9fsC4lG8Jxvyn1SL7qhb5sXVnjGTkC-yoqps4DjgrcZOQkqR6AMGefn_uwZitN_C_W_oh-Gr_WL9bwOFUq75LjTZnKXS2IhYrAg88DYxy0TUYjmly-q/s1600/IMG_6078.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img alt="JB KwikWeld Epoxy" border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjjBsLSGCj2HGunYsyf4lb5bIzoX9fsC4lG8Jxvyn1SL7qhb5sXVnjGTkC-yoqps4DjgrcZOQkqR6AMGefn_uwZitN_C_W_oh-Gr_WL9bwOFUq75LjTZnKXS2IhYrAg88DYxy0TUYjmly-q/s640/IMG_6078.JPG" title="" width="640" /></a></div>
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Once dried I pulled the duct tape off to see what I had. Kind of a freaky Mickey Mouse.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgpv9bn2GnOfRXSOwJpgUcwIcvr9u7yT13-T-TxQ6cNSVgtZxg4ww33q9Yi7r8jXyEEqUE1a-MRQynrzpcCIfEb8sIxeNhhZdSSO5hVUihqNb5Phdl5YZ-S0O8vsIwwCVsKzhpcif1ETgeI/s1600/IMG_6079.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img alt="JB KwikWeld Epoxy" border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgpv9bn2GnOfRXSOwJpgUcwIcvr9u7yT13-T-TxQ6cNSVgtZxg4ww33q9Yi7r8jXyEEqUE1a-MRQynrzpcCIfEb8sIxeNhhZdSSO5hVUihqNb5Phdl5YZ-S0O8vsIwwCVsKzhpcif1ETgeI/s640/IMG_6079.JPG" title="" width="640" /></a></div>
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After a bit of sanding I had this. Nice an smooth.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj888m8myF4o7X4yBMZ11Hb1bnriatWdNGFrNYzOI8FhUhp_8k1ZGSW465hMmiGGj-uQMYSVTuwZho0R9t11hXK0s7vg7EYgOYr83m7LjvgwaFpwr5scK6yvjuuNQXdKT9YC4Z-pF4Ehlan/s1600/IMG_6083.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img alt="What is this for?" border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj888m8myF4o7X4yBMZ11Hb1bnriatWdNGFrNYzOI8FhUhp_8k1ZGSW465hMmiGGj-uQMYSVTuwZho0R9t11hXK0s7vg7EYgOYr83m7LjvgwaFpwr5scK6yvjuuNQXdKT9YC4Z-pF4Ehlan/s640/IMG_6083.JPG" title="" width="640" /></a></div>
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Except for this . . . thing.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgGXfLYdfAbsINxB1J6OTZ-mFMUuVZ_V2EUWoW0f3fBiHzNz86yHAGd9kxxrC4apsG9VOpq5omgorGdlObXw5BNRnHC_U4H9AFUM1Tc-yWPZ6-hJ8hPIFjZr-yqjYP6X24bAMSqYvLomIPY/s1600/IMG_6086.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img alt="Bondo and JB fills all." border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgGXfLYdfAbsINxB1J6OTZ-mFMUuVZ_V2EUWoW0f3fBiHzNz86yHAGd9kxxrC4apsG9VOpq5omgorGdlObXw5BNRnHC_U4H9AFUM1Tc-yWPZ6-hJ8hPIFjZr-yqjYP6X24bAMSqYvLomIPY/s640/IMG_6086.JPG" title="" width="640" /></a></div>
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I used some body filler to fill it in, and then sanded it smooth.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjStukjYfSL78HftjPDkoLYu7lSneXXPTdL7bjsFFz1jwX9XXMsYSN7qCT3VbOKy4bW9MODIx9XY1MyPHyJywJVWA_P0XtxP4q0xWW59btZa5kP-na487B00Pt1-bdcj_QCvc9NICTDZEfN/s1600/IMG_6084.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img alt="AR80 tail plastic" border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjStukjYfSL78HftjPDkoLYu7lSneXXPTdL7bjsFFz1jwX9XXMsYSN7qCT3VbOKy4bW9MODIx9XY1MyPHyJywJVWA_P0XtxP4q0xWW59btZa5kP-na487B00Pt1-bdcj_QCvc9NICTDZEfN/s640/IMG_6084.JPG" title="" width="640" /></a></div>
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There were a few other places that needed some work.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEilCANZSVzi5akz6l6yTWwbPd0I0uIM3HXzt4bHwt7tarbnToN8XlPTqBtI8v034RESTbiXBswef7yYlkZbx7gZG0MKavqu3uL2UR1Q9sAuR6eNBNbfqKAGpm09zdtQ_UJm7_4jlcoVeWPE/s1600/IMG_6085.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img alt="AR80 tail plastic" border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEilCANZSVzi5akz6l6yTWwbPd0I0uIM3HXzt4bHwt7tarbnToN8XlPTqBtI8v034RESTbiXBswef7yYlkZbx7gZG0MKavqu3uL2UR1Q9sAuR6eNBNbfqKAGpm09zdtQ_UJm7_4jlcoVeWPE/s640/IMG_6085.JPG" title="" width="640" /></a></div>
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A little body filler and sanding took care of those as well.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg13vVjVoTcg7I0PXDO6kuPC_dXsBz-VMx3tzd-i3_sGeYuIgoEwfNy9swU5DIHTw6o1OV3THCvPqcBxKi2fkOytg-CXkNj7_QwAO5LUbm-RVOKVuIt3GwDRgZy06AkzJXdnKGpSiAl-cfM/s1600/IMG_6212.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img alt="Rust-oleum Plastic Primer" border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg13vVjVoTcg7I0PXDO6kuPC_dXsBz-VMx3tzd-i3_sGeYuIgoEwfNy9swU5DIHTw6o1OV3THCvPqcBxKi2fkOytg-CXkNj7_QwAO5LUbm-RVOKVuIt3GwDRgZy06AkzJXdnKGpSiAl-cfM/s640/IMG_6212.JPG" title="" width="640" /></a></div>
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After things were fairly smooth it was time for some primer. I grabbed some Rust-oleum Plastic Primer.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjdls79qzrD81V-zyTiLagHF9nIpCY3PGTXPTlgzX5n17BANE0vNn3zHuPoprREXz3WjccrFTzPMfetV5NJFfSo8A2jgXn8gkhguNwmAVilg0nIySiVqX6OcdVntKhteBYnCtjE9sh60D1O/s1600/IMG_6215.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img alt="Rust-oleum Plastic Primer" border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjdls79qzrD81V-zyTiLagHF9nIpCY3PGTXPTlgzX5n17BANE0vNn3zHuPoprREXz3WjccrFTzPMfetV5NJFfSo8A2jgXn8gkhguNwmAVilg0nIySiVqX6OcdVntKhteBYnCtjE9sh60D1O/s640/IMG_6215.JPG" title="" width="640" /></a></div>
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It will definitely need some more sanding and prep before final paint, but it looks good for now.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjPZGfSbDbG9q-k-vm5xImt8R5aiH5dQBdNJjueei55vsToov0izBqP4vNUjnMPzCls5dANa3xzEZrC0H-H683IHPjLsGxOMTmcxaURTgoytmoj3g04ef1ixhdDUG3FAX5kZY6pANsX6xoq/s1600/IMG_6380.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img alt=""Custom" Kawasaki AR80 tail plastic" border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjPZGfSbDbG9q-k-vm5xImt8R5aiH5dQBdNJjueei55vsToov0izBqP4vNUjnMPzCls5dANa3xzEZrC0H-H683IHPjLsGxOMTmcxaURTgoytmoj3g04ef1ixhdDUG3FAX5kZY6pANsX6xoq/s640/IMG_6380.JPG" title="" width="640" /></a></div>
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Finally, it was time to mount my new tail light.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjy1t1AHAB9e1g5i-LEjSioVraBudcTapMagrb3Jaipp_3BcijmlF7qJ3XduwDmfDFjNgyRNwImRP19x4W7y25c5bP8aUDpG0drRFHmPKHHYNNEmUWTS_kdjg54Ae7hLUlNYAUkxIop1qBr/s1600/IMG_6383.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img alt=""Custom" Kawasaki AR80 tail plastic with pimiento jar tail light " border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjy1t1AHAB9e1g5i-LEjSioVraBudcTapMagrb3Jaipp_3BcijmlF7qJ3XduwDmfDFjNgyRNwImRP19x4W7y25c5bP8aUDpG0drRFHmPKHHYNNEmUWTS_kdjg54Ae7hLUlNYAUkxIop1qBr/s640/IMG_6383.JPG" title="" width="640" /></a></div>
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Installed.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj6_LSGClbq3KIUqVbeJFicKlEcvdCAP9zqzVjeYbLmKbI8VZ5QvksXMlscSHC5baJaS2RCBfGh8LPgwnXcrCpNaDTXbGDFKX79O4ql0DIMKts0je5rIKwabEGF3bPYURS4BXzP1hTc1sjb/s1600/IMG_6384.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img alt=""Custom" Kawasaki AR80 tail plastic with pimiento jar tail light " border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj6_LSGClbq3KIUqVbeJFicKlEcvdCAP9zqzVjeYbLmKbI8VZ5QvksXMlscSHC5baJaS2RCBfGh8LPgwnXcrCpNaDTXbGDFKX79O4ql0DIMKts0je5rIKwabEGF3bPYURS4BXzP1hTc1sjb/s640/IMG_6384.JPG" title="" width="640" /></a></div>
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One hole. Nice and simple.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEigQwQDjv_lCOcqZjc9zNus1lcEoz7F0VMLDvAXWTT3-2jDZ_EfiH2DpPmcQZmihOsPzWW-00JsU3d8IKMsOThrY65I3PJ1MdLjYhGEr62tQLKLFsxX0XvSZtkVqW4SDyvvDgIpzwVQ8Y8-/s1600/IMG_6387.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img alt=""Custom" Kawasaki AR80 tail plastic with pimiento jar tail light " border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEigQwQDjv_lCOcqZjc9zNus1lcEoz7F0VMLDvAXWTT3-2jDZ_EfiH2DpPmcQZmihOsPzWW-00JsU3d8IKMsOThrY65I3PJ1MdLjYhGEr62tQLKLFsxX0XvSZtkVqW4SDyvvDgIpzwVQ8Y8-/s640/IMG_6387.JPG" title="" width="640" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhqS55gyk0bJGUYkdbaMJY0VgjaKVo44BUQwRTFeO-XwLftWfL1QBxTv4EgHxIrfPvv0WOBYLuWeAJZ7B-Mw5sWRcWT0jnRsOyNOqpcJf9bKI0Iq2n0_BKLblBQxuGIy2c_QkLV1h7z000p/s1600/IMG_6389.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img alt=""Custom" Kawasaki AR80 tail plastic with pimiento jar tail light " border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhqS55gyk0bJGUYkdbaMJY0VgjaKVo44BUQwRTFeO-XwLftWfL1QBxTv4EgHxIrfPvv0WOBYLuWeAJZ7B-Mw5sWRcWT0jnRsOyNOqpcJf9bKI0Iq2n0_BKLblBQxuGIy2c_QkLV1h7z000p/s640/IMG_6389.JPG" title="" width="640" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi4VoY96lwd9jKu-edCjQGsKtE1VZo25C4XMzE96lmtTfUjsDdVykAcSEQaZb96BX3pa0zUC5v0gO_EK_aYoltEbUu5EbgpmC2AQCOV9DZ_PghRFGdfBdFad8Kk3oIZj8_Ewr-iakglg3qt/s1600/IMG_6388.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img alt=""Custom" Kawasaki AR80 tail plastic with pimiento jar tail light " border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi4VoY96lwd9jKu-edCjQGsKtE1VZo25C4XMzE96lmtTfUjsDdVykAcSEQaZb96BX3pa0zUC5v0gO_EK_aYoltEbUu5EbgpmC2AQCOV9DZ_PghRFGdfBdFad8Kk3oIZj8_Ewr-iakglg3qt/s640/IMG_6388.JPG" title="" width="640" /></a></div>
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I think it looks pretty good.Unknownnoreply@blogger.com6tag:blogger.com,1999:blog-5387416435334481600.post-8416738660829777252015-08-09T00:29:00.001-04:002015-08-09T00:29:51.715-04:00Powder Coating Oven Extension<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4dR3OOVnJ6KGoS4Gk22dfl_jyaxKRno1YxmsaHzPuVA-qHfh1vlQUwiLQk6qiuX2RGd4p0LJxAJ70hd-XzSLqGG8CLc3ycZyMRISqieNZg_76PpfJ-C6w9blmu24HnqW-47UzyJAhvzP7/s1600/IMG_6314.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4dR3OOVnJ6KGoS4Gk22dfl_jyaxKRno1YxmsaHzPuVA-qHfh1vlQUwiLQk6qiuX2RGd4p0LJxAJ70hd-XzSLqGG8CLc3ycZyMRISqieNZg_76PpfJ-C6w9blmu24HnqW-47UzyJAhvzP7/s640/IMG_6314.JPG" width="640" /></a></div>
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For a while now I've been thinking about how to powder coat the AR's frame and swingarm. They obviously won't fit in my normal sized kitchen oven. Do I have them professionally done? Too expensive. Do I buy an infrared curing lamp? Too expensive. Do I buy a large powder coat oven? Too expensive. Do I build a larger oven? Maybe, but it seems like kind of a waste to build a whole second oven just to do a few larger items. Do I build some sort of oven extension box that allows me to use the oven I already have? Hmmm. Yea, that sounds about right.<br />
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Some googling revealed a number of ways to build such an extension. But they almost all involved buying stuff. I decided to forget all of those and try to mostly use stuff I already had laying around the garage.<br />
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First I removed the door and storage drawer. Oven doors are easily removable. I don't know why.</div>
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I constructed a platform that was roughly even with the bottom of the oven. The depth of the platform was based on the size of the random pieces of wood I had laying around.<br />
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I framed up a box and drywalled the inside with random scraps of drywall I had from a remodeling project from five years ago. I was making this up as I went along, so the construction is pretty janky.<br />
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I splurged and bought four rolls of aluminum foil from Dollar Tree and a couple of rolls of foil tape from Home Depot. About $20 in all.</div>
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I taped all of the drywall seams with foil tape. Its load bearing tape now.<br />
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I stapled aluminum foil to the inside walls and then sealed the seams with foil tape.<br />
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I tried to transition the foil into the oven as gracefully as possible. Its not easy.<br />
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I used some magnets to hold the foil to the inside of the oven because I wasn't sure the foil tape would hold up that close to the heating elements. That also means it should be pretty easy to separate the extension from the oven.<br />
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After the walls, ceiling, and floor were done, it was time to build a door. It was at this point that my wife came home from work and told me to make sure my life insurance was in order before I used this thing.<br />
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It would have been nice to build a door from a single piece of drywall, but that would have required buying a single piece of drywall. So I made a single piece out of random scraps.<br />
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I taped the pieces together with foil tape.<br />
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And then faced the inside with aluminum foil.<br />
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I used some clamps to hold the door to the box.<br />
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I shoved a yard stick under the door to create a bit of a gap to the floor.<br />
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And then used tape to make hinges. Cheap and easy.<br />
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Then I got fancy and added a handle.<br />
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Nice.<br />
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I decided I'd continue to use the clamps to hold the door tight to the box while baking.<br />
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I added four eyelet bolts to the corners of the ceiling to act as hangers. These where actually salvaged from an old Christmas tree stand, which I had gotten for free. Cheap.<br />
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With the extension built, it was time to give it a shot. Swingarm, you're up.<br />
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But not without precautions. At this point I thought there was a very good chance that the thing would burst into flames, so I bought a fire extinguisher.<br />
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And had the garden hose at the ready.<br />
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I did an initial bake at 200 degrees to "outgas" the swingarm and to test for heat leakage and/or a complete meltdown. But the extension handled it fine. So I cranked the oven up to 400. It took a very long time to get up to temperature.</div>
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While the box heated up, I shot the swingarm. When we finally hit 400 I put it in and set the timer for 20 minutes.<br />
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It worked!<br />
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But I think I put the powder on a little thick. I got some orange peel.<br />
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But you only see it if you get really close.<br />
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It still looks pretty good.<br />
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If I make sure that I don't go to thick with the powder the frame should work just fine. I've still got some prep work on the frame, so that will have to wait for a future post. Considering the fact that I only spent $20 on top of stuff I already had, I am extremely happy with my oven extension. Anything worth doing is worth doing right . . . . or for extremely little money . . . . and with little regard for proper construction techniques . . . . or safety.Unknownnoreply@blogger.com11tag:blogger.com,1999:blog-5387416435334481600.post-18772158507322997382015-03-21T19:53:00.000-04:002015-03-21T19:53:25.928-04:00Pimiento Jar Taillight<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhGPViMG_8FGKDMZxkHnwccNXSZ1vKDk78K2x-SpLFMEm6UyklFVdnOZXHxKja6W-WYPwhyphenhyphengb-0kH0ODl7ZnEaXCOz29ssfmCinLN1aFN3o2JpGluvkbGSqaCVU_rUo-m8xxlU5OOsoIxyH/s1600/IMG_6087.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhGPViMG_8FGKDMZxkHnwccNXSZ1vKDk78K2x-SpLFMEm6UyklFVdnOZXHxKja6W-WYPwhyphenhyphengb-0kH0ODl7ZnEaXCOz29ssfmCinLN1aFN3o2JpGluvkbGSqaCVU_rUo-m8xxlU5OOsoIxyH/s1600/IMG_6087.JPG" height="480" width="640" /></a></div>
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This empty pimiento jar has been in our Tupperware drawer for a while. One day I looked at it and thought "That would make a cool motorcycle taillight".<br />
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I ordered up a LED Supernova Brake Light from Revival Cycles. Its got three really bright red LEDs in a nice aluminum housing.<br />
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Just to see if this would work I drilled a hole in the jar's lid.<br />
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And attached the LEDs. This could work. Now the glass needs to be red.<br />
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No problem. VHT Nite-Shades is a transparent spray paint specifically for painting taillights.<br />
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As you can see from the picture, the paint didn't go down very well. The paint didn't come out of the nozzle well and I was left with little dark red specks all over the jar. It may have had something to do with the fact that it was about 40 degrees out when I painted it and the spray can specifically says to do it above 60. Oops.<br />
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Kinda looks like a strawberry.<br />
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After consulting the interwebs, I learned that some people do some wet sanding with 2000 grit sandpaper after using the Nite-shades to smooth things up a bit.<br />
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I sat in front of the TV with a basin of water and started sanding. Almost immediately I knew this was not going to turn out well. Some of the paint came off completely so it was clear again. Other places became hazy. I started thinking to myself "I wish I could powder coat this thing because everything I powder coat turns out awesome".<br />
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After consulting the interwebs again, I learned that it was in fact possible to powder coat glass. So I sanded off all of the Nite-shades to start over. Why I didn't just buy another $2 jar of pimientos instead of spending 45 minutes sanding the paint off of this one, I'll never know.<br />
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I ordered some translucent red powder from Eastwood.<br />
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It looked pretty pink, but I gave Eastwood the benefit of the doubt.<br />
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In order to get the jar to hold a charge, I jammed it full of aluminium foil.<br />
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Then I stuck some electric fence wire into the bottom in order to hang it and to give me something to attach my electrode to. I preheated the jar in the oven, took it out, hung it up, and attached my electrode.<br />
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Since the glass was already hot the powder started to flow out immediately. As soon as it started turning red I knew this thing was going to look awesome.<br />
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It looked so good I practically watched it bake for the full 20 minutes.<br />
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Amazing. If you have a piece of glass that needs to be a translucent color, I cannot recommend powder coating enough. It doesn't just look like I painted the glass red, it looks like red glass.<br />
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With the glass sorted, I turned my attention back to the lid. First, I powdercoated it black.<br />
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Then I added a bit of aluminum tape to the underside of the lid just to add a bit of reflectivity.<br />
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The LED taillight has a hollow threaded stud on the back that the wiring runs through. Here I just threaded on a nut to hold it to the lid, but eventually the nut will hold it on the bike's plastic tail piece. Nice and simple.<br />
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Sure, this looks like any number of cheap taillights I could have bought ready made, but I'm pretty darn proud of my pimiento jar taillight. At least I know I'll never see another one like it.<br />
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But does it work?<br />
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I hooked up a 9V battery to test it. Looks pretty good.<br />
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You don't get the sense of it from the picture, but this thing is super bright. The drivers of the cars behind me are going to have red dots in their eyes even after I take my foot off the brake.Unknownnoreply@blogger.com2tag:blogger.com,1999:blog-5387416435334481600.post-89689357393951278082015-01-18T22:53:00.001-05:002015-01-18T22:53:56.801-05:00The Pictures are a Lie<div class="separator" style="clear: both; text-align: center;">
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I've been questioned about the air of cleanliness portrayed in my pictures. Its a sham. I usually have stuff all over the place. For instance, this picture was taken while I was trying to remove my broken wheel stud.<br />
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It really bugs me when stuff other than what I am trying to take a picture of sneaks into the picture. On wide shots it can't be helped, but in tighter shots I obsessively eliminate extraneous items in the picture. This one didn't make the cut because the shop vac's wheel is visible in the corner. I should probably lighten up.<br />
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Also, for every good looking picture I post, I've probably taken five terrible ones like this.<br />
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Why such high standards and attention to detail? The Mayor demands it.Unknownnoreply@blogger.com1tag:blogger.com,1999:blog-5387416435334481600.post-71823287841388791692014-12-24T14:12:00.000-05:002014-12-24T14:12:21.268-05:00eBay FTW!<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEig7fQIvwQgAHbD5-SgRY0e_3g3WsBh5iDHcTLyeHbhxVaHEp73QY0-Y1rAuib9uiM7kXSZsxsSGtCaq5IEJE-OenrPTZw21-nYnb7mnz7G-rD0p50lcQ70dg7IrzAvDnUXJKDKgckOupja/s1600/IMG_5522.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEig7fQIvwQgAHbD5-SgRY0e_3g3WsBh5iDHcTLyeHbhxVaHEp73QY0-Y1rAuib9uiM7kXSZsxsSGtCaq5IEJE-OenrPTZw21-nYnb7mnz7G-rD0p50lcQ70dg7IrzAvDnUXJKDKgckOupja/s1600/IMG_5522.JPG" height="480" width="640" /></a></div>
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The image above is the reason I haven't posted anything for a while. When I realized I wasn't going to be able to repair my original gas tank I started combing the interwebs for a replacement. Since AR tanks are so rare I was even considering trying to use a tank from a different bike. Since a different tank might require frame and/or seat modifications the tank became somewhat of a linchpin for the continuation of the project. However, my diligent eBay scrounging paid off. I scored this sweet "new" tank from a guy in Portugal. I won the auction for $1. I'll let you guess what the shipping cost. Still, it was worth it.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLvvgIU8s2QUs8Ix5GQVgr3JpgTtXDXbQWVAn_A1YNY2kMCibnI0x8nf9NUPkXIWpqQStE3LQ9TBWf0eZ9Up7KExRv4pTJkWmMOWRXYuDLxNDh4KgaFFXQGDnEUPHrZDq3NxurGXv8T4At/s1600/IMG_2705.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLvvgIU8s2QUs8Ix5GQVgr3JpgTtXDXbQWVAn_A1YNY2kMCibnI0x8nf9NUPkXIWpqQStE3LQ9TBWf0eZ9Up7KExRv4pTJkWmMOWRXYuDLxNDh4KgaFFXQGDnEUPHrZDq3NxurGXv8T4At/s1600/IMG_2705.JPG" height="480" width="640" /></a></div>
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Here are a few reminders of why I needed a new tank.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjjp2QcVDXNdFikHUzZWBZABfbLnsXwup7cNmEHk1RkuRrS4CRo7JDVFxrHudKC7awgJ903Ye760ctZ6lw_c3l_RTHHnJBIJ4c04VPWxLdd-sbc6jeqNaFPtEe8l0VR1qRL9bIrLtEyzdFx/s1600/IMG_3671.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjjp2QcVDXNdFikHUzZWBZABfbLnsXwup7cNmEHk1RkuRrS4CRo7JDVFxrHudKC7awgJ903Ye760ctZ6lw_c3l_RTHHnJBIJ4c04VPWxLdd-sbc6jeqNaFPtEe8l0VR1qRL9bIrLtEyzdFx/s1600/IMG_3671.JPG" height="480" width="640" /></a></div>
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Yikes.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi_YpbxaAeixyTXSoJFb5dlJCRhqfiq9MqdJ6P912-tuhDGPmKkwtvWNTf4c3yFqTrVVNsOU9QLVNuBKDnUsSlyqBfyQIXNXC6Z1-2ifguvd6nJhOyAkvRtVOZW9iz8sZqw817VxMqRzGdA/s1600/IMG_2722.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi_YpbxaAeixyTXSoJFb5dlJCRhqfiq9MqdJ6P912-tuhDGPmKkwtvWNTf4c3yFqTrVVNsOU9QLVNuBKDnUsSlyqBfyQIXNXC6Z1-2ifguvd6nJhOyAkvRtVOZW9iz8sZqw817VxMqRzGdA/s1600/IMG_2722.JPG" height="480" width="640" /></a></div>
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I didn't have the skills for this.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEikhct9zeskI9A9yqlriBxKNz3aXYj-m49m53Z52FwrggNDBDjNzPYmJ2hNDqFgTT27Bvu4nEutNnjGqhzrYHkMGv8wGk1Ytdi49TaUGHhXQzao9PIIR85x00ChgxHbxf7_Lv1ycCYKvd3q/s1600/IMG_3670.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEikhct9zeskI9A9yqlriBxKNz3aXYj-m49m53Z52FwrggNDBDjNzPYmJ2hNDqFgTT27Bvu4nEutNnjGqhzrYHkMGv8wGk1Ytdi49TaUGHhXQzao9PIIR85x00ChgxHbxf7_Lv1ycCYKvd3q/s1600/IMG_3670.JPG" height="480" width="640" /></a></div>
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That is just nasty.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEigwWxoftG9_4ELdWI6sngJykM1JT2dyhVCEcHdpPeABOzbn9hg9wI8lgAjmVt7P3LVLmjiY4-r289SpW3lfO8zioptHG54vcmPiDMPVgpECptjRmlRWIwnx8bieBT8Fk6MSgz3UCNhDYk4/s1600/IMG_5523.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEigwWxoftG9_4ELdWI6sngJykM1JT2dyhVCEcHdpPeABOzbn9hg9wI8lgAjmVt7P3LVLmjiY4-r289SpW3lfO8zioptHG54vcmPiDMPVgpECptjRmlRWIwnx8bieBT8Fk6MSgz3UCNhDYk4/s1600/IMG_5523.JPG" height="480" width="640" /></a></div>
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The new tank has a few minor issues of its own. A little surface rust on the back where the seat presses against it.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2T2bB_nzXkMOS6fJcrVot9P8Td_Yfx63f4cJMzf_ulWQZWo7k1IqJHwrAFAB8Xrbb7i6CeY-rU1ZPRbY68wzRBRNaR0tS0QXEjxx0DeD30t2pVtJjWV4ylbpWth6-MyXZHaYHw6vxIjcO/s1600/IMG_5527.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2T2bB_nzXkMOS6fJcrVot9P8Td_Yfx63f4cJMzf_ulWQZWo7k1IqJHwrAFAB8Xrbb7i6CeY-rU1ZPRbY68wzRBRNaR0tS0QXEjxx0DeD30t2pVtJjWV4ylbpWth6-MyXZHaYHw6vxIjcO/s1600/IMG_5527.JPG" height="480" width="640" /></a></div>
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A little rust inside, but nothing compared to my original tank. I'll probably do a POR-15 kit or something like that to reseal the inside.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjXZZMTHUas5LqgWRV5u1udqnOznVRLTXxcFGyV_6fJdolvd3BKcxY_oL04KAD-3JOEfC5d8mJ5pMv3eDsC1ENEgjFDtHbYbB3wAYfeULcQ8b70z6kX_e8AHD5QdVjXvTlz3lanQOfaMLQW/s1600/IMG_5524.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjXZZMTHUas5LqgWRV5u1udqnOznVRLTXxcFGyV_6fJdolvd3BKcxY_oL04KAD-3JOEfC5d8mJ5pMv3eDsC1ENEgjFDtHbYbB3wAYfeULcQ8b70z6kX_e8AHD5QdVjXvTlz3lanQOfaMLQW/s1600/IMG_5524.JPG" height="480" width="640" /></a></div>
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The tank came with the super hard to find oil tank cover. Since my bike didn't come with one this was a major win. This tank is off of a slightly newer AR that came with a locking gas cap that is attached to the tank with a hinge.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhaKpfVVFXuhPTNJ2uQ0db44rIN8N6GxgiumWIi2LBZQVUqVk4Vekj-EvMA6OTwZHT9i86zUxLm-MAmvIb4c-FJOv4LlIUtG_d0vG-ChFs0axko5Z3CfTcsH6CiM1B3SFiJfcuDhl_fYqF_/s1600/IMG_5529.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhaKpfVVFXuhPTNJ2uQ0db44rIN8N6GxgiumWIi2LBZQVUqVk4Vekj-EvMA6OTwZHT9i86zUxLm-MAmvIb4c-FJOv4LlIUtG_d0vG-ChFs0axko5Z3CfTcsH6CiM1B3SFiJfcuDhl_fYqF_/s1600/IMG_5529.JPG" height="480" width="640" /></a></div>
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The tank also came with a petcock that is way better than my original. Score.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrXdQnkCtBG5q_IQ3-YPT2wd0IX1jX9U3bDZTcMOb6YJjQquPtO09fD0TDPsI8jzNzCFH_1VjG4gBehNaqpyf1mhKRVOLVI6t7U1Gt8W3_MAnTAgtBRSg7FsKVl3xeJp_mzdjZt-WrUyyH/s1600/IMG_5535.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrXdQnkCtBG5q_IQ3-YPT2wd0IX1jX9U3bDZTcMOb6YJjQquPtO09fD0TDPsI8jzNzCFH_1VjG4gBehNaqpyf1mhKRVOLVI6t7U1Gt8W3_MAnTAgtBRSg7FsKVl3xeJp_mzdjZt-WrUyyH/s1600/IMG_5535.JPG" height="480" width="640" /></a></div>
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The bottom looks pretty good. A little surface rust, but nothing major.<br />
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With the amount I paid to ship this thing I would have imagined a nicer box and a some more packing material. Its a wonder the tank arrived in as good a shape as it did. But I don't blame the eBay seller. He had to make money somehow.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjAQ807wodXpM1VoQe423XQnC8fXcQ-WbhF7BZheIG_obe0BNvXMdx1Eis4TuM3WZ2Yk_c_Lg-a74fRk80tSB52OFn6vteHfz4mQ6KyCzb9nZnUWq4-uXREKIX8rXwaLV7-2rxDTxbcAbqq/s1600/IMG_5539.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjAQ807wodXpM1VoQe423XQnC8fXcQ-WbhF7BZheIG_obe0BNvXMdx1Eis4TuM3WZ2Yk_c_Lg-a74fRk80tSB52OFn6vteHfz4mQ6KyCzb9nZnUWq4-uXREKIX8rXwaLV7-2rxDTxbcAbqq/s1600/IMG_5539.JPG" height="480" width="640" /></a></div>
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Here is the oil tank cover cleaned up up a bit.<br />
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I disassembled the gas cap to get all the gunk out.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgeJKRililHGBbFSfGz-z7XeVBvBvkmWed4HB0yPqwTqt3IRyY2cxokJRLA2QzmPJDLtiqcLfT5vIsSOU6gb_157I_R-J3OFeFdw0-MdSsI50m2cAhevE-s_SkRK4dQil0D-bafsnkPhfw/s1600/IMG_5540.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgeJKRililHGBbFSfGz-z7XeVBvBvkmWed4HB0yPqwTqt3IRyY2cxokJRLA2QzmPJDLtiqcLfT5vIsSOU6gb_157I_R-J3OFeFdw0-MdSsI50m2cAhevE-s_SkRK4dQil0D-bafsnkPhfw/s1600/IMG_5540.JPG" height="480" width="640" /></a></div>
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The gas cap is kind of pitted. If I can figure out how to take the hinge apart I'll powder coat it black, which should smooth it out a bit.<br />
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I absolutely loved the 80's style graphics the tank had. Sadly they were all scratched up and I needed to remove them to fix a few dents.<br />
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A heat gun and a putty knife made short work of the graphics.<br />
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They look so sad.<br />
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Out came the Aircraft Remover to take off the paint.<br />
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I took a hand sander to the places with surface rust and then applied some Krud Kutter to prevent it from coming back. This seat area rust was the worst. I got it pretty smooth so it shouldn't show up once painted.<br />
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There were a number of small dents that needed to be filled prior to paint. This one on the top was the worst.<br />
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Here are a couple of the dents on the side.<br />
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Overall it wasn't too bad.<br />
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This shot gives a better view of the dent on top.<br />
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Look at the brazing on the gas cap drain line. Pretty cool.<br />
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I've never done any body work before, but it didn't seem like brain surgery so I figured I'd give it a try. I bought a container of Bondo, a few spreaders, and a pack of stepped grit sand paper.<br />
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The Bondo comes in two parts. A base and a hardener.<br />
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Delicious.<br />
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When you mix the two parts you only have a few minutes before it hardens. How do I know that? Because my first batch hardened before I even got it on the tank. D'oh.<br />
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I started with the dent on top of the tank because it was the biggest and on a fairly flat surface. First, I roughed it up a bit with some sand paper to give the Bondo something to grab on to.<br />
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I then applied a coat of Bondo and waited for it to dry.<br />
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Then I used gradually finer grit sandpaper to smooth it out. This is after 60 grit.<br />
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100 grit.<br />
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150 grit.</div>
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220 grit. You can see in the center of the dent that there was some air trapped in the middle of the Bondo. So I went ahead and applied another coat of Bondo and did the whole process again. I'm pretty sure that is how body work like this goes. Bondo, sand, assess, repeat.<br />
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I did the same for all of the other dents in the tank.<br />
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When I'm waiting for Bondo to dry, paint stripper to work, powder coat to bake, etc I throw darts to pass the time. I was going for 19s in this pic. Not too shabby.<br />
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Once I was generally happy with my body work I gave it a coat of primer. A real body guy would call this a guide coat. Applying some primer makes it easier see how good a job you did filling your dents.<br />
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One of the harder dents to fill was right on the contour on the side of the tank. If you look closely at this picture you can see a little irregularity where I didn't quite get it right.<br />
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This looks pretty good. You can't see where that seat area rust was at all.<br />
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Nice.<br />
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The top dent is totally gone.<br />
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Ah, but one of the side dents is still visible here. No worrys. I just applied more Bondo to the still visible dents and sanded them again.<br />
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I applied another coat of a lighter color primer to see how I did.<br />
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I'm really pleased with the results. Its still not perfect, but perfect is the enemy of the good. I'm going to set it aside until I'm ready for final paint.Unknownnoreply@blogger.com1tag:blogger.com,1999:blog-5387416435334481600.post-56481023465198435042014-06-15T22:48:00.000-04:002014-06-15T22:48:52.268-04:00Front Brake<div class="separator" style="clear: both; text-align: center;">
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The AR's front brake worked when I broke the bike down, but it needed a bit of a refresh.<br />
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Step one was clean out the sludge that used to be the old brake fluid.<br />
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Step two was strip the old paint. Same formula as always. Aircraft remover followed by sanding blocks and elbow grease.<br />
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The reservoir window was seriously discolored. Luckily the spare master cylinder that came with the bike had one that is still somewhat transparent.<br />
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On the original bike the mirrors screw into posts on the front controls. Since I won't be using the stock mirrors I decided to see if I could get rid of the post.<br />
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I cut most of it off with the Dremel and a cut off wheel.<br />
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I used the benchtop grinder to remove as much material as I could and then switched to sanding drums on the Dremel when I needed finer control.<br />
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Finally I used a hand sander to get things as smooth as possible. Unfortunately there was still a little bit of a divot where the mirror mount was. Since I couldn't weld it (its aluminum) I decided to fill the divot with Quiksteel like I did on my top triple clamp (which was steel and could have been welded if I owned a welder at the time). When I did the top triple I learned that the Quiksteel would expand in the oven, so I baked it and sanded it smooth again before powder coating it.<br />
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After things were stripped and sanded I masked them off to get ready for powder.<br />
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Here they are after powder, ready to go in the oven.<br />
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You can barely tell that there was ever a mirror mount on there. Just a little dimple.<br />
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I did two layers of powder on all the parts. They came out nice and smooth.<br />
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For reassembly I consulted my trusty service manual.<br />
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Step five of the reassembly instructions for the caliper reads:<br />
<blockquote class="tr_bq">
Install the dust seal around the piston. Check that the dust seal is properly fitted into the grooves in the piston and caliper.</blockquote>
While that sounds simple enough, it might as well say:<br />
<blockquote class="tr_bq">
Construct a rocket ship out of cardboard and fly to the moon.</blockquote>
Getting that stupid dust seal in there is the reason why so much time has passed since my last update. I tried it multiple times with no success. Finally today I had the right combination of patience and luck to make it work. Part of the trick was applying a bit of brake fluid to the seal to get it to slip in place. I put the seal into its groove on the piston and pushed it into the caliper. Then I worked my way around the seal using a small screwdriver to push the seal down into its groove in the caliper.<br />
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Here is the caliper fully assembled.<br />
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When the caliper and master cylinder were done I installed them on my front end assembly. That way it'll be ready to go when its time to reassemble the bike. If I keep up my blistering pace that should be midsummer of 2020.Unknownnoreply@blogger.com2tag:blogger.com,1999:blog-5387416435334481600.post-74255434052926034712014-02-25T22:21:00.001-05:002014-02-25T22:21:55.884-05:00Welder<div class="separator" style="clear: both; text-align: center;">
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I do not know how to weld. But I've been scouring craigslist for cheap welders so I can learn. I picked up this beauty for $30. Its a Montgomery Ward Powr Kraft 110V, 50amp stick welder. It has zero adjustment. You just turn it on and go to town. It'll weld up to 1/4" metal using 1/16 rods.<br />
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Side note: Powr Kraft? Nothing instills confidence in a tool that can seriously harm you like a brand name that includes misspellings on purpose.<br />
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Vintage.<br />
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Yep, its basically just two big coils of wire.<br />
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I bought some gloves.<br />
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And a cheap welding mask. The mask was extremely lame so I decided to paint it.<br />
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Thats more like it. Primer red.<br />
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With the proper protection, a box of electrodes, and zero skills I found a simple non-structural project to start on. When I cut the chain guard mount off of the swingarm I left a couple of grooves. I decided to try laying a couple of welds in the grooves so I could grind them smooth.<br />
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This thing leaves some dirty welds.<br />
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A whole bunch of grinding and sanding later this is what I have. Not perfect, but certainly better. After powder coating it should look OK.Unknownnoreply@blogger.com5tag:blogger.com,1999:blog-5387416435334481600.post-48084107406181550402013-12-15T16:47:00.000-05:002013-12-15T16:47:36.704-05:00Gold Rush: Kentucky<div class="separator" style="clear: both; text-align: center;">
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The AR comes with some sweet rims. But these had been ridden hard and put away wet. The gold was faded quite badly. In some places (about 7:30 in this pic) the gold was almost gone and you could see the bare aluminum. The machined lips were all scratched up and oxidized.</div>
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A little aircraft remover and some time with a sanding block made pretty short work of the stock gold.<br />
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Sanding blocks, steel wool, and a lot of elbow grease got the machined lips pretty shiny. Then, I used a felt wheel on the Dremel along with some polishing compound to really shine them up.<br />
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The lips were full of nicks and scratches, so I knew they were never going to be mirrors. But I am happy with how well they ended up looking.<br />
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I used high heat tape to mask off all the machined surfaces so I could lay down the gold first. Masking off the rims was quite difficult. By the second side of the second rim in the second half of the second hour I had gotten the hang of it though.<br />
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Here you can see the wire I used to hang the rim for shooting. I had to make sure that the rim hung at an angle so it would fit in the oven. If it hung level the door wouldn't shut.<br />
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I did a number of "dry runs" to practice moving the rim from the hanger, onto the oven rack, and then into the oven.<br />
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Once I had it down, I shot the gold and popped it in.<br />
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I did two coats of the gold. Then I pulled the tape off the lips and shot a layer of super gloss clear.<br />
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The clear powder goes on white. It looks like powdered sugar. Delicious.<br />
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After shooting and baking I was left with a big pile of tape. . .<br />
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. . . and two slick looking Enkeis.<br />
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This one really shows the shine on the lips.<br />
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Three coats of powder leaves a pretty smooth finish, even on the rough cast aluminum.<br />
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Masking the machined lips off was an exercise in extreme patience. It certainly would have been easier to do gold on the whole thing. But boy did the time and frustration pay off. I love the way the machined lips look next to the gold centers. With the clear over the whole deal, hopefully they will stay looking this good for years to come.Unknownnoreply@blogger.com4tag:blogger.com,1999:blog-5387416435334481600.post-72374201479165317392013-10-29T21:01:00.000-04:002013-10-29T21:01:33.731-04:00Suspension Linkage Bushings<div class="separator" style="clear: both; text-align: center;">
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Some of the suspension linkage bushings were in pretty rough shape.<br />
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So I ordered up some new ones.<br />
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I had already cleaned up and powder coated the linkage. So all I had to do was press in the new bushings.<br />
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<br />
These bushings were actually in pretty good shape, so I decided to reuse them.<br />
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This is a fairly lame update, but I'm pretty jazzed with these pieces. They look factory.Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-5387416435334481600.post-91328103014196489662013-10-29T20:49:00.000-04:002013-10-29T21:02:29.971-04:00Wheel Breakdown<div class="separator" style="clear: both; text-align: center;">
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I started pulling the wheels apart so I can prep them for powder and polishing.<br />
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The rear brake pops right out.<br />
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The rear sprocket is supposed to be held on with four nuts. But as you can see, one stud is broken off completely. More on that later.<br />
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Once the brake and sprocket were removed I could pull out the bearings, lock ring, spacer, and seals.<br />
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Tire irons are the tool of choice for pulling off old tires, but I figured out that a plastic putty knife and a big flat head screwdriver do a pretty good job of prying off tires without marring up the rims.<br />
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Here is the broken sprocket stud.<br />
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My first removal attempt involved using a bolt extractor. These are sometimes referred to as "easy outs". The people that call them that have obviously never used one.<br />
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First you drill a hole in the center of your broken stud.<br />
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Then you left hand thread it into the hole and give it a couple of taps with a hammer. That is supposed to let you turn the extractor and stud out of the hole together.<br />
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I grabbed the extractor with a vice grip and tried to turn the stud out. But it did not want to move.<br />
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So I clamped the extractor in the bench vice and tried turning the wheel.<br />
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That was a little too much mechanical advantage. The extractor snapped off in the stud.<br />
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Nice.<br />
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My next attempt at extraction involved a set of left handed drill bits. These let you use your drill in reverse in hopes that the bit will "bite" and you'll turn the broken stud out with the bit.<br />
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However, the bits never "bit". I just kept drilling with larger and larger left handed bits until all that was left of the stud was the threads.<br />
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So I just chased the threads out with a tap.<br />
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Stud extracted. Now I just need to find a replacement stud.<br />
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The front rotor also put up a fight. Four bolts came out fine. But one wouldn't budge and I stripped the allen head on it.<br />
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I tried cutting a phillips head into it and beating it out with my impact driver. It didn't move.<br />
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I managed to get it out by clamping the outside of the bolt head with the vice grips.<br />
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My plan is to powder coat the hubs and spokes gold, polish the lips, and then clear the whole thing.<br />
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This is a test piece I did with the powder I plan to use on the wheels. These things are going to look good.Unknownnoreply@blogger.com4tag:blogger.com,1999:blog-5387416435334481600.post-33918837041267865052013-09-10T22:35:00.000-04:002013-09-10T22:35:08.737-04:00Front End<div class="separator" style="clear: both; text-align: center;">
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The stock handlebars bolt onto the ends of the top triple clamp and are extremely lame. So I decided to go with clip on handlebars and a "modified" triple clamp.<br />
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First I cut the ends off with a Dremel cutoff wheel.<br />
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I used a permanent marker to color the remaining area that I planned to remove.<br />
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I removed the material with the grinding wheel on my bench grinder and then smoothed things out with some sandpaper.<br />
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The triple clamp is made of separate top and bottom plates welded together. When I cut off the ends I was left with a big ugly gap to fill.<br />
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Since the triple was going to get powder coated I needed a way to fill the gap that would stand up to 400 degrees. I found this Quiksteel High Temperature Metal Repair that is supposed to be like a "cold weld" and can stand up to 2400 degrees. It was pretty cheap so I gave it a shot.<br />
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I glombed the stuff on and let it harden for a couple of days.<br />
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Then I sanded it smooth. I was really jazzed with how it turned out. . . until I powder coated it and baked it. When I read that the Quiksteel could stand up to 2400 degrees I erroneously assumed that it would keep its shape. During the baking the Quiksteel kind of pushed its way out of the gap leaving the surface a little rougher than the picture above. I somehow misplaced the close up pictures of the finished top triple, but I can assure you that even with the rough ends it came out looking pretty good.<br />
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You'd be surprised how hard it is to find clip ons for 27mm forks. I snagged these from treatland.tv which is actually a site for moped parts. But chrome wouldn't do, so I powder coated them black.<br />
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With the forks, triples, and clip ons all cleaned up I assembled the front end. Not too shabby.<br />
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<br />Unknownnoreply@blogger.com2tag:blogger.com,1999:blog-5387416435334481600.post-25015754221047274392013-07-22T13:06:00.000-04:002013-07-22T13:06:12.579-04:00Forks<div class="separator" style="clear: both; text-align: center;">
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The front forks on the AR were looking pretty tired, so I decided to rebuild them. When I took the bike apart and set the forks aside I applied a coat of Krud Kutter to the uppers because they had some scratches that had begun to rust. The mottled look of the uppers is from the dried Krud Kutter. It did a great job of getting rid of the light rust though.<br />
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First, I removed the top caps and emptied out the old fork oil. I don't know what color it was when it went in, but it came out a dark and nasty brown. It also stunk to high heaven.<br />
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The oil seals were actually in decent shape but a ton of dirt and grime had gotten under the dust seals.<br />
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According to my service manual a special tool is required to disassemble the forks. This tool is basically a long shaft with a T-handle and a tapered square end. Since I didn't have this special tool I got a 3/8" square rod and ground down the end to a point. I actually ended up grinding it "sharper" than in this picture.<br />
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The tapered end gets jammed into the top of the "piston and cylinder unit" down inside the fork so you have something to hold onto while you loosen the Allen bolt on the bottom of the fork. I had good luck with the first fork by pressing the rod end hard against the wall while I loosened the bolt with an Allen wrench. The second fork decided to be difficult.<br />
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For the second fork I had to use my hand impact driver. This neat little tool is for removing stubborn bolts and screws. You hold onto the outer sleeve and hit the top of it with a hammer. The inner core has a bit on the end and is splined such that the impact force is transferred in a downward and counterclockwise motion simultaneously. This impact force is more than can be generated by a constant force from turning an Allen wrench. It took a bit of hammering but I broke it loose. I learned later that applying some heat would have been a good idea. What a n00b.<br />
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With the fork disassembled you can see the cup at the top of the "piston and cylinder unit" that the special tool gets jammed into. Evidently a lot of forks work this way. I don't know why they wouldn't put at hex head down there instead.<br />
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To get the old oil seals out of the lowers I had to apply a bit of heat with a heat gun. I was then able to pry them out with a screwdriver. In a bunch of pieces.<br />
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Accept for a few scratches the uppers were actually in pretty good shape so I decided to clean them up a bit and go with them. I got them damp, shook on some Bar Keeper's Best Friend and gave them a light scrubbing. Not bad.<br />
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After stripping and powder coating the lowers I was ready for reassembly.<br />
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I ordered some new oil seals off of ebay. The rest came from a local shop: New 5w fork oil, Loctite for the bottom Allen bolt, and liquid gasket for the bottom gasket.<br />
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Note to the world: Use the liquid gasket liberally. I assembled the forks a couple of times only to have the new oil leak out of the bottom. That is not especially fun after you've applied Loctite to the bolt and left it to set up. I had to heat up the bolt with a propane torch and then whack it with the impact driver to get it out again.<br />
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My service manual was invaluable through this whole process.<br />
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The service manual said I needed another special tool to install the oil seals. But I just used a large flat head screw driver to gently seat them into place.<br />
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The service manual specified 83 - 91 cc of oil. That seams like a large range. I went with 90 for no other reason than its nice and round.<br />
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There they are fully assembled and looking the business.Unknownnoreply@blogger.com4tag:blogger.com,1999:blog-5387416435334481600.post-23413627368250426852013-05-14T23:27:00.001-04:002013-05-14T23:27:56.083-04:00Shock cleanup: Part Two<div class="separator" style="clear: both; text-align: center;">
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This is the rear shock after being relieved of thirty years of grime and grit. Way better than it was when I got it, but still not great. I decided to remove the spring so that I could give it a nice coat of gloss black powder coat. Disassembling the shock would also let me clean up some of those other hard to reach cracks and crevices. But disassembling a shock like this is no easy task. The spring must be compressed so that you can remove the retaining ring. Then you can release the spring and remove it from the shock. Easier said then done. The spring holds a lot of energy so I needed a way to do this "safely".<br />
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A quick look around the garage yielded three lengths of threaded rod and hardware that I got from my grandpa as well as some aluminum stock left over from another project. Throw in a 2x4 and you've got the makings of a spring compressor rig.<br />
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I cut the aluminum bar into 3 four inch pieces and drilled holes for the threaded rod in the ends. I drilled a hole in the 2x4 just smaller than the adjustment ring on the bottom of the shock as well as three smaller holes around it for the threaded rod.<br />
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I arranged the aluminum bars in a triangle around a loop in the spring just above the retaining ring that I needed to remove. The rods and shock were then fed through the 2x4 and held in place with washers and nuts. These top nuts are what I would use to compress the spring. Tightening the nuts caused the aluminum bars to move up slowly, thereby compressing the spring. I alternated between the three nuts giving each one a few turns at a time, pulling up each corner of the triangle slowly and evenly. As the force built up the aluminum started to bend and make strange groaning noises. At this point I wished the triangle sides were steel instead of aluminum and that I was wearing shoes instead of flip-flops. As I slowly cranked on the nuts I was sure that something was going to break, sending the shock flying at the floor and then back up to disfigure me and my garage.<br />
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But she held together. Once the spring was compressed a couple inches I could remove the retaining ring you see at the bottom of the picture. I then reversed the process by loosening the top nuts to slowly let the spring relax. This let me remove the spring and the plastic sleeve halves.<br />
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A little Aircraft Remover and some time with the wire wheel got the remaining crud and paint off the spring so I could powder coat it.<br />
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The plastic sleeve halves were really scratched up so I hit them with some fine grit sandpaper to smooth them out a bit. Then I used some Armorall to "bring back the black". I used a scrubbing pad and the wire wheel to clean up the metal shock body and retaining ring. There are still some gouges and scratches in the metal but it doesn't look too bad.<br />
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After everything was cleaned up it was back into the spring compressor rig for reassembly. This time I was slightly safer as I slid rod through the clevis so that I might be spared in the event of catastrophic spring compressor rig failure.<br />
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Here is the final product. I am really happy with the way it turned out.<br />
<br />Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-5387416435334481600.post-52491027601597941322013-04-08T00:03:00.001-04:002013-04-08T00:04:03.744-04:00Powder Coat<div class="separator" style="clear: both; text-align: center;">
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When we moved into our house I noticed two outlet boxes in the garage with wires sticking out. I didn't give them much thought until I started thinking about installing a powder coat oven in the garage. An oven needs a 220v outlet. Four element wire like this is common for 220v wiring, but there were no 220v breakers in the panel. When I went up into the attic I could tell that the wire from these boxes went in the direction of the breaker panel, but it wasn't going into the box. Curious.<br />
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Then I pulled off the wood above the breaker panel. Aha, the previous owner ran wire for 220v, but stopped short of pulling it in the box and wiring in a breaker. Thank you "Sparky". All I had to do was pull the wire into the box, wire up the breaker, and wire up the outlets. Sweetage.<br />
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I needed 220v to install this. The free oven I scored from someone at work. Why was it free?<br />
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The story is that a drunken roommate came home hungry for pizza, and during the process of making it managed to crack the glass top range. But the oven still worked. When they heard I was on the lookout for a cheap oven, they hooked me up for free.<br />
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It was free, but it did need a good cleaning. It might have been fine for baking edibles but I am going to be putting my motorcycle parts in there.<br />
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Is it bad that the only oven I've ever cleaned in my life is the one in my garage?<br />
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The 220v outlet is awkwardly high on the wall so I had to modify the oven's plug to come out higher in order to reach. Once my oven was squared away it was time to get a gun and some powder.<br />
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Powder coating works by applying dry paint to the part and then baking it with high heat to cure the finish. The paint gets an electrical charge as it leaves the tip of the gun while a wire lead from the gun gives the part an opposite charge. This causes the paint to "cling" to the part prior to baking. The resulting finish is really hard and durable. Most powder coat guns require an external air compressor to shoot the paint, but I found one, the Craftsman Powder Coating System that has the required air compressor built in. People online say that it works pretty well and I was able to score one for a decent price on eBay.<br />
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Eastwood is basically the go-to place for powder. I ordered one pound of their gloss black.<br />
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Eastwood sent a free sample of Five Hour Energy with my powder. Thats weird.<br />
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I used a washer as my first test piece.<br />
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Here it is hanging in my super high tech paint booth.<br />
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Here is the washer after its been sprayed. It goes on looking matte black and becomes glossy after baking. You can see the alligator clip hooked onto the hanger. This is what charges the part, causing the powder to stick.<br />
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After spraying it goes in the oven for about 20 minutes at 400 degrees Fahrenheit.<br />
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Not bad at all. After this success I stripped the parts that I had already spray painted and started powder coating them. I used high heat masking tape, silicon plugs, and tin foil to protect the surfaces and threads that I didn't want to get powder coat on.<br />
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The parts look awesome. It seems like a lot of trouble to get the 220v outlets, the oven, and the gun but after seeing the finish I think it was totally worth it.<br />
<br />Unknownnoreply@blogger.com1tag:blogger.com,1999:blog-5387416435334481600.post-16499816172242491492013-03-05T22:20:00.002-05:002013-03-05T22:20:23.551-05:00Frame mods<div class="separator" style="clear: both; text-align: center;">
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I cut the mounts for the side covers and the helmet lock off of the frame. The Dremel, with a couple of cut off wheels and grinding discs, made pretty short work of the job.<br />
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I've still got a little more grinding to do to smooth things out, but I like how clean the center "triangles" look now.Unknownnoreply@blogger.com1tag:blogger.com,1999:blog-5387416435334481600.post-24284017802583133072013-02-14T22:39:00.001-05:002013-03-05T22:20:38.784-05:00Swingarm mods<div class="separator" style="clear: both; text-align: center;">
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The AR80 has a pretty sweet looking swingarm, but its big ugly chain guard has to go.<br />
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Thats better. But the mounts need to go too.<br />
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I went at the mounts with a cut off wheel on my Dremel.<br />
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I had to cut of the "wings" of the front mount in order to get at the welds with the cut off wheel. Once they were cut down I knocked it off with a hammer and screwdriver.<br />
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I cut a tad too deep when cutting the front mount off. But a grinding wheel and sanding drum cleaned things up pretty well.<br />
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I didn't totally grind away the cuts from removing the front mount. They shouldn't show too much once its painted. I might even fill them in with some silver solder or JB Weld.Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-5387416435334481600.post-37501544450134230402013-02-13T23:10:00.002-05:002013-02-13T23:10:22.952-05:00Paint Test<div class="separator" style="clear: both; text-align: center;">
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A motorcycle frame should be painted with a real paint gun or should be powder coated professionally. I've been reticent to buy a paint gun myself because I think it would take real skills to use. Skills I don't have. I'd really like to get everything powder coated, but that seems a bit expensive for this cheap little bike. So, I've been researching spray paints that might do the job. The problem is that for every person who says a certain spray paint is awesome, there is another who thinks its terrible. I finally just went to Home Depot and bought some spray primer and paint that looked like it could work. The Rustoleum Professional High Performance Enamel is for industrial applications and is supposedly good looking and durable. I painted a few small parts to see how it would look.<br />
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This is a bit of suspension linkage. I've removed all of the old paint and pulled out the pivot bushing.<br />
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If you look closely you can see that the primer left a pretty rough finish. So I hit it with fine sandpaper to give a smoother base on which to paint.<br />
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This picture makes it look pretty good. But what you can't see is that there is still a bit of an orange peel effect. You wouldn't notice it unless you got right up to it, but I'd know its there and that would bug me. I might try some more light sanding and another coat, but I don't know if that'll do it.<br />
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Again, the finished kickstand looks pretty good from a few feet way, but up close its kinda rough.<br />
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With my hopes somewhat dashed I've been looking into what it would take to do my own powder coating. It actually looks pretty achievable. You can get a gun for around $50 bucks. The powder itself is fairly cheap. The only other thing I'd need is a way to bake it. Today my garage doesn't have a 220v outlet, but if I installed one I could go get a craigslist oven to bake most of my parts. I would probably still have to get the frame itself coated by a pro. But I'd feel good about doing the rest myself. I haven't given up completely on spray paint. I still have some of the black left so I might try some more sanding followed by another coat of black.<br />
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Confession: I'm lazy. I had convinced myself that I would just spray these things with a couple of coats of primer and a couple coats of paint and they would come out looking the business. I guess its going to take a little more effort than that.Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-5387416435334481600.post-54473984307446902432013-02-10T03:17:00.001-05:002013-02-10T12:45:11.760-05:00Shock cleanup<div class="separator" style="clear: both; text-align: center;">
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The rear shock has been sitting on my work bench looking at me all nasty like. So I finally cleaned it up. I sprayed it down with the hose and then hit it with a scrub brush. The dirt and grime were resilient, so I had to soak it with some wheel and brake cleaner and then scrub it again.<br />
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It looks a lot better. The chrome bits have some cracking and unfortunately the spring has some rust and missing paint. Looks like I'll need to figure out how to disassemble this thing in order to restore it back to its former glory. That, or find a deal on a new one. Also, when it comes to replicating four "before" and "after" shots like this, its better to be lucky than good.</div>
Unknownnoreply@blogger.com1tag:blogger.com,1999:blog-5387416435334481600.post-13636497337771709552013-01-13T14:18:00.000-05:002013-01-13T14:18:58.622-05:00Even more paint prep<div class="separator" style="clear: both; text-align: center;">
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I'm almost done stripping paint off of miscellaneous frame parts. Here are two pieces of rear suspension linkage. I decided to use another one of my new tools to strip them down.<br />
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My "new" benchtop grinder came with a wire wheel on it which makes short work of stripping small pieces.<br />
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It only took a few minutes to get the majority of the paint off. I did have to use a bit of stripper to get the paint off the surfaces that I couldn't get up to the wheel.Unknownnoreply@blogger.com1tag:blogger.com,1999:blog-5387416435334481600.post-58634107735688493372013-01-01T16:14:00.000-05:002015-01-18T22:54:49.371-05:00Happy New Year<div class="separator" style="clear: both; text-align: center;">
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I got a whole bunch of old tools from my Grandpa over Christmas, one of which is this heavy angle grinder. And when I say heavy, I mean heavy. I've been using it to strip paint off the frame and I have to take a break every couple minutes to give my wet noodle arms a break. But I must say, the wire brush head really does a good job taking off paint.<br />
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Other than a few hard to reach places the frame is stripped down. There is a bit of rust in a couple places that I'm going to treat with Krud Kutter. I also plan to clean up the frame by cutting off the passenger peg mounts and side cover mounts.<br />
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Since its finally gotten cold around here I picked up this little heater to warm up the garage a bit. Its never going to make it 72 degrees in there, but it keeps it comfortable. Not bad for $20.<br />
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With the heat and The Mayor's solemn look of approval I'll be D'ing W in 2013.Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-5387416435334481600.post-60244295247651536912012-12-19T12:10:00.000-05:002013-01-01T16:15:46.408-05:00Paint prep continues<div class="separator" style="clear: both; text-align: center;">
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I basically finished up the swingarm and then got started on the triple clamps.
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I've also started on the frame. I figured the frame was going to take forever, but I found a better chemical stripper that may make it a quicker job.
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I picked up some Rustoleum Aircraft Remover because its quite popular with the online motorcycle crowd. So far its worked well.
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The Aircraft Remover has a big airplane on the can so when you look at it on the shelf you think "Whoa, they use this stuff to strip paint off of 747s!". But then you read the directions on the back and it says "Do not use on aircraft". That's just not right, Rusty.Unknownnoreply@blogger.com1tag:blogger.com,1999:blog-5387416435334481600.post-68473654393679733482012-12-09T16:59:00.000-05:002013-01-01T16:15:27.020-05:00Paint prep<div class="separator" style="clear: both; text-align: center;">
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Today I started prepping some of the smaller parts for paint. I used some chemical stripper to start and then finished up with sanding pads. The shifter, brake pedal, and kick stand are ready to go. The swing arm is going to take forever. I should really just bring these things to someone with a sandblaster. But then what would I have to do on a rainy Sunday morning?<br />
<br />Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-5387416435334481600.post-86808975520507568902012-12-09T16:39:00.000-05:002012-12-30T00:04:50.986-05:00Yes, disassemble<div class="separator" style="clear: both; text-align: center;">
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. . . all over the place. I finally broke the bike down completely.<br />
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Here it is at the roller stage. The rear suspension on this bike is kind of unique in the way that the shock is nearly vertical in the center of the frame and gets compressed downward via the linkage. My plan is to run without the side covers to show off the shock. Side note: nobody makes a better light motorcycle stand than Wells' Blue Bunny in Le Mars, IA.<br />
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I didn't realize the steering stem used loose ball bearings. They bounced all over the garage when I dropped it out. I don't think I found them all.<br />
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As you can see many parts were covered in dirt and grime, so I sat down with a bucket of soapy water and scrubbed them down. I also let rusty parts soak in a can of Krud Kutter.<br />
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After scrubbing the parts down I arranged them neatly on my workbench like a huge nerd.<br />
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I've ordered a couple of A123 LiPoFE4 cells to build a smaller, easier to hide battery. Since I won't be using the side covers I'm going to fab up a tray to hold the battery, flasher, and igniter under the rear of the tank.<br />
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The engine ran when I got the bike, but it leaked oil. I'm going to clean it up and replace the gaskets, piston rings, and reeds. I'll also rebuild the carb and give the whole thing a nice coat of gloss black engine enamel.Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-5387416435334481600.post-39382727153892885322012-11-30T18:12:00.002-05:002012-11-30T18:12:51.947-05:00Tank repair . . . attempt<div class="separator" style="clear: both; text-align: center;">
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After some searching around the interwebs, I found out that some people use a silver based solder to do basic tank repairs. The nice thing about this is that it doesn't require as much heat as brazing so you can just use a propane torch. It's fairly cheap, so I picked up the supplies and gave it a try.<br />
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I chose a smallish dent on the side of the tank for my first attempt. It was previously filled with a bunch of JB Weld.<br />
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I rested the tank on its side, brushed on some flux, and heated up the dent. Then applied the solder.<br />
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I ground it down with the Dremel and then sanded it smooth. Its hard to tell from the picture, but it turned out pretty well. So I moved on to the pitted and pin-holed front section of the tank.<br />
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That didn't go well for a few reasons. Some of what I thought was pitted metal was more JB Weld. While trying to heat up the metal I actually burnt away a bunch of it. So now I have more holes. Once I got the metal heated up the solder didn't want to flow into the dents or build up to cover the holes. It wanted to form a useless, giant ball of molten solder which would run off the side of the tank and/or run through the hole into the tank. Before it cooled I would try to spread it out with a piece of wood, but that didn't really work either. When I moved on to fill the next hole I would reheat, and undo, the work I had already done. I need to rethink my technique. At least I did a good job on the first dent.Unknownnoreply@blogger.com0