1978 gs1000

[Loki]

Had a few hours to start taking it apart. Soaked all bolts and screws in Kroil last weekend, no issues removing any so far. Got the valve cover off, looks good in there at first glance. Did some rust removal on the gas tank, some moderate pits but its salvagable so far.

 

[Guest]

Soaked all bolts and screws in Kroil last weekend, no issues removing any so far.

Shocking...

 

[Loki]

Shocking...

It is, I thought the exhaust bolts would fight more from the looks of them

 

[Loki]

Stripped the tank exterior. Last color underneath was Pearl Black Bluing, the teal metallic color. Tail piece looks to be the same under the dark and medium blue coats.

 

[Guest]

No dents on the tank? ... Shocking...

 

[Loki]

Got it down to the frame, swing arm and front end, will finish it tomorrow and then blast the frame.

Broke a bolt off in the cam chain tensioner, other than that been fairly easy so far. The gas tank is another issue, gonna have to split it open to save it or not, we'll see.

 

[Loki]

Is this bracket a seat stop? I don't have the correct pan and the parts fiche kinda shows it but no description. It has a screw and a tab on the inner side

 

[Rover]

Helmet holder.When the seat is down it secures the helmet.

 

[Loki]

Helmet holder.When the seat is down it secures the helmet.

Shweet, thank you :clap:

 

[Loki]

So I'm thinking I was wrong about the teal metallic color being Pearl Black Bluing, I think it is the darker blue color that was on it. Looking at the color chart there were only 3 base colors available, Black, Pearl black bluing and the Deep Burgundy metallic, can anyone else confirm that?


Split the gas tank at the old weld, ground out and blasted the rust away, have some metal to replace around the lower corners and a couple pin holes but not to bad. Will post some pics tomorrow. Frame is blasted, welds and all look good.

 

[Loki]

Got about half the metal work done, still more welding to do on the patches but you can get the idea. Will grind the exterior and then braze over them. The rest of the metal in pretty good shape after the rust removal.

Crack and rust hole patch

Edge patch, was not much metal left after removing the rust

 

[Loki]

and 1 more, inside of the tank, not a view you get to see often

 

[steve murdoch]

So that is what the inside of a paper mache gas tank looks like.
Great thread, Loki. I am reading all of it.

 

[Rover]

Ditto!
Inside the belly of the beast,show us the other half please.

 

[Big T]

So I'm thinking I was wrong about the teal metallic color being Pearl Black Bluing, I think it is the darker blue color that was on it. Looking at the color chart there were only 3 base colors available, Black, Pearl black bluing and the Deep Burgundy metallic, can anyone else confirm that?

Black - E model with white stripe

Blue -standard model,deep metallic blue (the tank color) That's what yours is

Burgundy -Standard model - see Nvr2old posting of Chucks tank in Appearance forum

I had a choice of all 3 colors when I bought my blue one

 

[Guest]

Split the gas tank at the old weld

How do you do this?

I have an old tank that needs that sort of treatment...

 

[Loki]

Black - E model with white stripe

Blue -standard model,deep metallic blue (the tank color) That's what yours is

Burgundy -Standard model - see Nvr2old posting of Chucks tank in Appearance forum

I had a choice of all 3 colors when I bought my blue one

Fantastic, thank you. I did a search and never did see a teal colored 78, must have been the overspray of the darker blue that I was seeing under the tank and tail piece.

 

[Loki]

What i did was cut just below the old fusion weld all the way around the underside of the tank (basically cutting the bottom out). The old material is about 1 mm thick or .040 and the patch and replacement metal I'm using is 18 ga, just a bit thicker. I split the bottom again into 4 pieces, 1 of which I can re-use. I will fabricate the other 3 pieces then lap joint weld them back together along with the petcock mount plate, fuel sending unit and weld on the front tank mounts. Then seal all of the inside leaving a couple inches around the bottom edge to weld the bottom back on, seal the seems after welding. I'm gonna use aircraft tank sealer, PRC-1422 A 1/2, outta out live me


Pics of the bottom half

Did not realize this year tank metal was so thin, yikes

the 4 pieces

forward tank mounts, after drilling off the spot welds

 

[Loki]

Ok, frame has been primed with PPG PAC 33 urethane over a light coat of P99 wash primer. Gonna let it cure a while before color and clear, maybe 2 weeks weather permitting. Posting this in the parts wanted section, need a few parts ha ha:

1) Fork tube uppers (straight please, trade my bent ones if you want)
2) Seat, non step type, torn cover ok.
3) Under seat trim
4) Grab rail
5) 2 turn signals assemblies (going on the front so no brackets needed)
6) 2 side cover badges, non "E" type (I have 2 E ones if anyone is looking)
7) Headlight assembly (I have the ears, need the rest)

Let me know what you have and how much $$$ :dancing:

 

[Rover]

Wow that tank was ruff,lucky you have welding experience.

Responded to your parts inquiry,in the parts section.
I have a 78 tank I may part with if your fix doesn't work out.