My 78 1000c needs some love

[chuck hahn]

Frame painted tonight along with the swing arm and all the engine mounting brackets. Sort of reminded me of a deer carcass swinging off the tree limb.


Got these emblems too....not a matched set but I had them laying around. The points one is more akin to the original one on the Cooley. Whats you guys opinion on if I should use them on the Maroon C??? I checked and they are the correct sizes.

And paint pics........

 

[Big T]

Frame painted tonight along with the swing arm and all the engine mounting brackets. Sort of reminded me of a deer carcass swinging off the tree limb.


Got these emblems too....not a matched set but I had them laying around. The points one is more akin to the original one on the Cooley. Whats you guys opinion on if I should use them on the Maroon C??? I checked and they are the correct sizes.

QUOTE]

Use the points cover badge and rehab the stator cover one. Or is that a big rash I see on it?

 

[chuck hahn]

It is rashed....goota file and dress up the cover a little at the very bottom edge.

 

[chuck hahn]

Its Chinese laundry day in the shop

Its Chinese laundry day in the shop

Ran some wire off the MIG and made hanger hooks and a parts dryer line. Got everything stripped and repainted. Will let it all hang and cure while I go about doing the rims and all the other polishing. She will be all back together end of next weekend...exactly 2 weeks to the day from final disassembly.

 

[chuck hahn]

Worst part is over

Worst part is over

Today was clean and polish the rims and clean engine mounting hardware. Wire wheeled all the bolts, washers, and nuts then applied liberal amounts of Wizards Power Seal for Motorcycles and rubbed it in till almost dry. Let it all set for about an hour and then rubbed them all clean with a fresh towel.

Took aluminum polish on some 000 grade steel wool and rubbed out each individual spoke as well as I could..what a LONG LONG process!! Then went back over all of them with the Power Seal and wiped them all down yet again.

Some may think my OCD got a bit carried away, but I even polished up the rear sprocket a bit.

Polished up the forks too.

 

[chuck hahn]

Reassembly has commenced

Reassembly has commenced

Got a good jump on reassembling the old girl tonight. Probably get the rear wheel. calipers, and rear caliper stay put on tomorrow night at a minimum. Will see how far I get when i turn off the lights.

 

[chuck hahn]

About 2/3 done

About 2/3 done

Got a good start today. As you may remember I had just the front end and wheels on a few days ago. Today I got the following done..in just over 6 hrs.

Polished all the engine covers and installed them ( new gaskets )

Put on the rear caliper, rear master cylinder and rear break line.

Set the battery box and the put all the electronics on the side moun ting plate thing.

Installed the turn signals

Put the engine in the frame. I actually timed myself for this and it was setting in the frame with the lower tranny bolt and front long engine bolt installed in just over 10 minutes. My engine stand and dedicated "engine board" for on the floor jack make this almost effortless now.

Ran the wiring harness and installed the rear light assembly. Now just to hook all the plugs back up. Install the horns, front brakes and handle bar switches, coils, bleed the brake systems and body kit. Gotta put in the air box and carbs too. I had said 2 weeks till finish and the bike will be done Sunday...2 weeks to the day from disassembly.

 

[Morrison]

Looking good so far. Chuck what paint did you use on the engine?

 

[chuck hahn]

VHT Hige Temp Engine Enamel.. Universal Aluminum. Part # SP-127.

Frame is VHT Epoxy Paint in Gloss Black. Part # SP-850

 

[Morrison]

Did you use a clear on the frame or engine?

 

[chuck hahn]

Nope....just shot it and let it cure a week while i was prepping all the other stuff. I think clear will only dull and yellow over time anyway. Its not a concourse resto..but it does look good.

 

[Morrison]

Indeed it does. My engine is fairly clean, but is indeed dull. So ill be getting the same paint if you dont mind because it looks that good.

 

[nvr2old]

Looks great, Chuck. That's a ton of work for 2 weeks. You're getting very proficient at tearing down, refinishing and re-assembling these GS's.

 

[Frank Z.]

Nice man. Did you lay the frame over motor for install, or upright slide-wiggle-thru method?

 

[chuck hahn]

Frank...I made an angle iron framed stand with casters and a steel table top thats exactly level with the highest point on the frame where the mount plate bolts up. Then I cut a 2X6 that sets on top of the floor jack. Set the board between the frame at the right height, roll the engine up, slip it thru onto the board and lower it in between the rear tranny mounts. Slip in the lower tranny bolt and use the jack to lift the engine and line up the other ones. Wrapped the frame with cardboard to protect the paint.

Larry.....Sorry to break this to , but all engines stopped for a while. Broke off an exhaust flange bolt. Got a nut welded to it right now and cooling. If that fails it will be drill it out and dig the core out with a pick. Ive done both before and I DO NOT prefer option 2!!

 

[Morrison]

Frank...I made an angle iron framed stand with casters and a steel table top thats exacltly level with the highest point on the frame where the mount plate bolts up. Then I cut a 2X6 that sets on top of the floor jack. Set the board between the frame at the right height, roll the engine up, slip it thru onto the board and lower it in between the rear tranny mounts. Slip in the lower tranny bolt and use the jack to lift the engine and line up the other ones. Wrapped the frame with cardboard to protect the paint.

Larry.....Sorry to break this to , but all engines stopped for a while. Broke off an exhaust flange bolt. Got a nut welded to it right now and cooling. If that fails it will be drill it out and dig the core out with a pick. Ive done both before and I DO NOT prefer option 2!!

Im always working on my stuff by myself so I was pondering the idea of how im gonna get the engine off my bench into my frame.. can I possibly get a picture of your setup?

 

[chuck hahn]

Jim..I will get some pics in the next day or so.

 

[chuck hahn]

Had to drill the bolt out

Had to drill the bolt out

After two welded nuts and no love, I had to drillit out and refresh the threads with a tap..But its all good now. Man I just hate when this stuff happens.

 

[chuck hahn]

And the finished product

And the finished product

Short of oil in the engine its all back together. Here is the spot that was damaged originally...

And some of the bike with her new make over....

 

[Guest]

Looks good, Chuck!
Now go out and ride the damn thing!