Project Windjammer

[Matchless]

Andre,

How does the repair look when peering through the cubby openings?

Dale,
The inside is either covered with a bead of slurry or with a strip of ABS sheeting. The long handled artists brushes made that quite easy from the inside. I have test fitted the flasher lights and they fit well.

Some building up with slurry, dry and sand to get level is still required as the slurry forms a dry scab very quickly as the acetone evaporates and if you disturb the surface it becomes uneven and thus easier to rather sand down slightly for a tidier finish.

Your cutting plan was perfect and made it quite easy to get together again!

 

[Matchless]

Way cool! Now it is starting to look more familiar! What color is it gonna be ?

Chuck,
Suzuki 08D Marble Lemans Blue. The colour it has now is very close to that. The Suzuki striping for that model and colour matches the Windjammer V decals very well, so those will go back on.
My work will probably grind to a halt as from this weekend onwards as the family start arriving for Christmas and new year.

Forming the windshield is going to be another challenge, but that will be next years worry!

Keep well.

 

[rustybronco]

Your cutting plan was perfect and made it quite easy to get together again!

Andre,

As you well know, there were a lot of sleepless nights spent on 'both' our sides of the pond over this project. mine was 'mostly' spent on not handing over a piece of junk you could not work with and throwing your money down the drain; cutting it was the easy part.

additional comments...

a thin coat of 'good' automotive body filler applied to the 'visible' portions should level the surface nicely and remove the final pin holes in the slurry if need be.

apply tape on the textured surfaces where the slurry is applied from that side.

 

[DanTheMan]

It sands quite well and yes there should be no seam as you can see. Its just a bit of a slep having to wait a day or two for the slurry to dry before sanding.

I am planning to use my bikes OEM headlight which already has a H4 Silverstar in it. I have not tried to fit it with the Windjammer V type headlight shroud. Hope it will fit though! I will check that out, thanks.
I must actually remove that cable for the painting and will pop the spade connectors from the H4 plug anyway.

The OEM won't work, I tried it, that's why I gave the one from my parts bike to Dave8338. I bought a sealed beam replacement H4 from these people: http://store.candlepower.com/ca7inquhhe.html , fits right into the 'jammer headlight bucket perfectly and plugs into the sealed beam socket. No extra engineering required there. No plug adapters required either. The Candlepower people were real easy to work with as well.

 

[rustybronco]

The OEM won't work, I tried it, that's why I gave the one from my parts bike to Dave8338.

Odd... my '80 Windjammer IV had the stock Stanley 7" H4 headlight capsule in it when first purchased. now it has a Bosch H4 in it.

Andre, I can include the Bosch capsule that came with that Windjammer in the next shipment if needed. let me know...

 

[Planecrazy]

Dan,

I don't recall exactly what bucket I have in the Windjammer, but it is NOT a sealed beam Silverstar ... This one uses the typical 9003/H4 bulbs and works beautifully in the Jammer. The ONLY mod is the switch from the long plug to a shorter one. Otherwise it's plug and play!

Regards,

 

[Matchless]

The OEM won't work, I tried it, that's why I gave the one from my parts bike to Dave8338. I bought a sealed beam replacement H4 from these people: http://store.candlepower.com/ca7inquhhe.html , fits right into the 'jammer headlight bucket perfectly and plugs into the sealed beam socket. No extra engineering required there. No plug adapters required either. The Candlepower people were real easy to work with as well.

I have just taken my OEM Stanley headlight with separate H4 Nightbreaker bulb off the GS1000G and it fits perfectly in the Vetter headlight shell. You just need to remove the inner mounting ring from the headlight to make it fit. In actual fact the positioning lugs on the headlight fit into the positioning slots on the Vetter shell

It will not fit when using the longer H4 connector, but works perfectly with the standard shorter one and the wires can even be moved into the slot in the shell made for that purpose.

Thanks for the tips and advice.

 

[Matchless]

Odd... my '80 Windjammer IV had the stock Stanley 7" H4 headlight capsule in it when first purchased. now it has a Bosch H4 in it.

Andre, I can include the Bosch capsule that came with that Windjammer in the next shipment if needed. let me know...

Thanks, but no need! The Stanley on my bike fits perfectly, just tested it.

 

[Planecrazy]

Told ya so, told ya so! :-\\\

Glad it worked out as expected!!

Regards,

 

[Matchless]

First test fit:
Next is preparing for painting and having the decals made.

Mounting bracket and Windjammer to check how it fits. Joining and sanding joints are complete.

 

[rustybronco]

I see a trunk and saddle bags in your future!

 

[chuck hahn]

now thats more of how i remember last seeing it!! looks awesome.

 

[Matchless]

I see a trunk and saddle bags in your future!

Don't put ideas in my head! I first have to recover from the past shipping costs. My doctor has advised me to take it easy with such things and to rest a while before making any more stressful decisions!

I know that if I first tile the back stoop, my wife will also think a set of Vetter boxes would be nice on the bike!

 

[Matchless]

now thats more of how i remember last seeing it!! looks awesome.

Chuck,
Obviously the next step is the painting and that may be my first project for 2011. The lowers have already been made to fit and I will have the decals made before I start prepping it for painting.

I must say my present windshield looks like a mosquito screen compared to the size of the Windjammer screen!

I think I recall you had one stipulation, it had to go to a good home!
I assure you that Windjammer is the happiest Windjammer in the country!

 

[rustybronco]

I know that if I first tile the back stoop...

Ahhh yes... you must tile that stoop! someday it would be nice to have a fine looking spot to pull those weeds.


(for those not knowing, it's an inside joke which started along some point when first discussing this project. 'it's better than sitting on the stoop and pulling weeds )

 

[Planecrazy]

Nice job! I am incredibly impressed!!

Look forward to seeing the finished project after paint, etc...

Regards,

 

[dr_fosg8]

That is amazing to me! Nice work. I had no idea plastic could be reassembled and be strong like that.

What is that shiny black exhaust you have?

 

[Matchless]

That is amazing to me! Nice work. I had no idea plastic could be reassembled and be strong like that.

What is that shiny black exhaust you have?

The exhaust is a Cowley 4 into 1 with street baffle.

I have used all sorts of epoxy's and super glues in the past which do not really work too well, especially when repairing broken posts or tabs and only discovered this method recently which is quite widely discussed if you search on Google. After a few quick experiments with some scrap ABS I was amazed at the result. The only real drawback is that it needs time to dry out and is only applicable to ABS plastic

I know from many years back that Chloroform is an excellent solvent for Perspex (Acrylic) and I still have a printer stand made from Perspex and glued together with chloroform!

 

[Matchless]

The Windjammer V decals have just arrived about $9.50 same day.
Excellent service by our local advertising signage people!

 

[rustybronco]

They did a very fine job reproducing those decals!

I suppose you're thinking of having decals made for the lowers and your 'newly' acquired luggage?
http://cgi.ebay.com/ebaymotors/ws/e...0538203925&viewitem=&sspagename=STRK:MEWAX:IT