Assembly Begins

Sunday was the day to put the engine back together.

A new head gasket was placed on the jugs and then the head went on top of that, the bolts were tightened to 29 ft/lbs making sure to tighten them from the center out. Mark & I then installed the cam chain sprocket paying close attention to aligning the holes parallel to the head, the exhaust cam was then guided through the hole in the sprocket which was a challenge because of the lobes on the cam changing from one side to the other. The intake cam was much easier because the sprocket is attached to the cam. Once the cams were in place the bushings were installed to hold them in place, each bolt was tightened to 12 ft/lbs. The final item to be installed and adjusted was the chain tensioner / guide.

The valve cover seal was installed then placed on the engine. That was definitely a woo hoo moment.

The next task was to remove the stearing head races which was quite a chore on account of they had to be cut out of the stearing head. While we had the cutter out we cut the bearing off of the triple tree because it fell apart when we tried to remove it.

This is the new top end race

We also attached the center and side stands because it is easier to get at them when the frame is upside down.

The engine was propped up on blocks of wood so that we could place the frame onto the engine, the frame was bolted back together and bolted to the engine.

BEFORE

AFTER

The last two items that went on the bike were the swingarm and the battery box.

Yes the swing arm is being held up by string because the shocks aren't ready to go back on the bike yet.

It's begining to look like a bike again!

All in All a good days work!

Painting Again

Monday - Saturday

During the week it is tough for Mark and I to have time to work on the bike together so I decided that it was a good time to paint the engine and a few other misc parts. The first step was to scour all the loose paint off then clean it really well so that the paint would stick. I also sanded some of the surfaces to get a nice smooth finish, especially on the clutch cover and the sprocket cover. The center bolt of the clutch cover got a polish and then was masked off. The painting was done in two stages the bottom side one night and then the front side the next night.

The final night was the finicky work - I decided I needed a little purple on the engine so I removed the bolts holding the clutch cover and the ingnition cover they were painted purple. All of the bolts being attached to the frame will also be painted the same purple.

I also painted the Honda logo on the clutch cover silver and the number of the gear positions on the sprocket cover.

I finally finished polishing the valve cover and clear coated it.

The last thing I did was finish polishing the front forks and attatched the reflective decal .

Busy working away

I haven't had much time to myself lately but I am still working away little by little on the bike.

This past week has been crazy at work so when I get home I crash, but I did get both of my helmets pin stripped and Friday I finally clear coated the remaining painted pieces of my bike ( tank, side covers, front & rear fenders, rear cowl, helmets and assorted emblems )

Saturday

I attached the crystals on to the stator.

I was able to finally take apart the spray booth that I created in my shop and cleaned up so that Mark & I would have room to work on rebuilding the engine

I decided it would be nice to see all the parts of the bike laid out

Today was the day to start work rebuilding the engine

The cam shaft journals were the first thing that came off then the chain tensioners were loosened off so that we could remove the cams.

Each part is being removed and placed on paper in the same layout as it was on the engine, it is very important that everything goes back in the right place.

The bolts holding the head on were the next thing to be removed, they had to be slacked evenly so that the head wouldn't warp. Each of the twelve recieved 1/4 turn starting from the center out then start over from the center again each bolt recieved 1/2 turn. Once the pressure was off the bolts they could be removed easily.

Once the head was removed the next challenge was to remove the valves all 16 of them, all of the parts of each of the valves were placed in a labeled bag.

Underside of the Head

The black in the before picture is carbon
In the after picture the valves have been removed and the carbon has been removed by grinding

Before---------------------------------------------------------After

Topside of the jugs- those are the pistons covered in carbon that was ground away.

Before---------------------------------------------------------After

The last thing of the day to lapp the seals for the valves.

Another item purchased

Bought these reflective stickers to put on my front forks.

Been feeling seriously under the weather the last few days, so I haven't been doing much decided I should figure out how I am going to polish my valve covers. Bought a set of buffing wheels and some cleaning compound and that seems to be working a little better than just using my fingers but I still need to get a larger one for the flat areas and a pointed buffer to get in all the corners.

Been Busy Painting!

Friday the 6th I clear coated the wheels

They look kind of blue in the picture but they are most definitely purple

Saturday the 7th I primed the tank, side covers, fenders and rear cowl.

Sunday was the fun day I primed the panels again then the color went on, two coats of the dark purple then a light coat of the lighter purple using some netting as a stencil it turned out looking like a cross between dragon skin & camo.

Monday I tried to start painting the final decorative painting but my airbrush decided it didn't want to work anymore so off to the store to buy a new one by the time I got home it was to late to start and I still had to tape off the design on my small helmet. So that was my chore for the evening.

Tuesday I was feeling pretty under the weather but I pushed myself to get to work and I am glad I did because I am really happy with how it turned out.

This is only the first step of the process no other pictures you will all have to wait and see it in person!

The next tasks are - to clear coat all the panels.

- finish polishing all the parts - front forks, stator cover, valve cover

One other idea I came up with was to add crystals on the stator cover there is a grove on it that they fit into perfectly, Mark thought it was a silly idea but when he saw it he thought it was cool

27 days left!

The pressure is begining to get to me! I am hardly sleeping and all I think about is getting my bike done.

Today at work I created a stencil for the flame paint job I am putting on the tank and side covers because the one I ordered is going to be back ordered for another week or two and I can't wait any longer.

I decided it was time to clear coat the frame, the color is getting closer to what I wanted. YEAH!!!

I also painted the kickstand using the same technique I used on the center stand.

Tomorrow when I get home the frame is coming in the house and I start painting the wheels and swingarm.

Small projects

I am working on completing small projects because I am still waiting for a stencil to paint the tank, side covers and fenders.

Decided it was time to start painting some of the black parts, the first victims were the battery box, assorted parts and the rear brake stabilizer they each got a nice shiny coat of black paint.

The center stand also needed a coat of paint as well but seeing as it takes a little bit more abuse than the battery box I decided to use a trick that Mark mentioned awhile back. After cleaning the part place into the oven heated to 300F once the part is heated thoroughly remove from oven spray with paint, once paint is dry place back in oven for two hours to cure.

The next task was to figure out a way to attach my new signal lights to the front forks, the old lights were bolted onto the flange sticking out of upper fork covers, the new lights need to bolt through the cover. The best solution was to cut down the flange so that the bolt for the signal light could reach the nut on the inside.

Left side of picture is the after

The last project tonight was to clean off the rust on the inside of the fork covers as best I could then spray with alluminum rust paint.