Cleaning up aluminum covers on 82 GS1100

[GP1200X]

I need to repolish one or two engine side covers since they have some corrosion taking place. What is the best way to remove the clear coat finish thta Suzuki installed on them 40 years ago. I hate to do it but I really need to fix two spots that look a little rough. I tired several products I have on hand but nothing seems to dissolve the coating. Just buff it off??

[oldGSfan]

Paint remover works just keep an eye on it, it's probably not good to leave on there a long time. That said, it's always worked just fine for me.

[Nessism]

(after stripping paint)...Sisal Wheel w/black cutting compound. This setup will make short work of the polishing. If the corrosion is really bad, 220 grit sandpaper on a DA can be used first.

[Burque73]

This stuff is amazing.

https://shop.advanceautoparts.com/p/aircraft-aircraftremover-oz-ear2000/12073054-P

It's rank though. Use outside away from anything you don't want to poison and of course PPE!

Some before and after pics.

https://flic.kr/p/2kW7TPx

It will strip the paint too so I masked off around the Suzuki emblem and sprayed it, then used lacquer thinner to carefully wipe around the letters.

https://flic.kr/p/2mYTEc4

Not as good as other folks around here, but good enough haha.

Oh, a drill and polishing wheel and polishing compound. Do this outside if you can as well as it's messy.

https://flic.kr/p/2kZaBYV

[GP1200X]

Thanks all! I think I will buy all the items listed above and give it a try. I have the buffing compounds, buffing wheels and machine machine. My ultrasound machine cleaned all the parts well but would not remove the clearcoats so I'll try the paint remover and aircraft spray.

[Suzukian]

I removed the paint with course Jewelers rouge, then polished them to a Chrome appearance, using a very light rouge. If I get a spot, a 2 second buff takes it out. I'll never spray paint them again. I've done most of the covers this way, and it looks excellent.

[rphillips]

Wondered for a long time of a way to get a more OEM silver look, for the covers, than polishing? The polishing I've seen and done just don't look anywhere near OEM, looks more like chrome..Yes, looks excellent but not OEM.

[Nessism]

Wondered for a long time of a way to get a more OEM silver look, for the covers, than polishing? The polishing I've seen and done just don't look anywhere near OEM, looks more like chrome..Yes, looks excellent but not OEM.

Like I said, sisal wheel and black cutting compound. It's a coarse grind, that shines, but not mirror like. Using a fluffy wheel and fine grit polish results in a shine that's too bright for guys looking for the OEM look.

P1020637 by nessism, on Flickr

[salty_monk]

I used a range of scotchbrite type pads on a dremel. The finest one gives an ok OEM looking finish. Not as good as others here though!

[Suzukian]

You can wire brush to get the look, but if you had a milling machine to get the wire brush wheel for an O.E.M. look you might be able to pull it off. There's no way for that finish to last though. The clear coat gets water under it, and if you leave it unpainted, it corrodes and looks cr@ppy.

[chuck hahn]

I keep telling you guys that if you use a rouge called BLACK MAGIC it will clean and polish to a chrome look in ONE STEP. I can do an entire bike including forks in about 3 hours. Just use paint stripper to get the clear off before buffing. Do whatever way you wish but i read a lot of multi step merthods that just waste time and energy.

[Suzukian]

The rouge I used smooth the covers and polished them to almost chrome. I could have left it duller, but I just "went for it". I don't think it took me anywhere near that long. Many roads to the same place.

[chuck hahn]

Are you talking about te entire bike in under 3 hours?? Im talking eery cover, sprocket cover and both forks.

[Suzukian]

My forks are black. Just the side covers. I had to do the clutch, so I was able to do it on the bench. No, I'm not Superman, I definitely could not do what you did in 3 hours, 3 days, yeah, not 3 hours though. Next valve adjustment time, I'll do the top cover. Had it glass bead blasted to remove the yucky clear coat. The motor won't be very visible once I get the Lockhart Lowers on it anyways.

GS750ES w Lockhart Lowers.jpg

[chuck hahn]

Im no superman eiter..lol. BUT i was turned onto the black magic rouge many years ago. Honestly itll eat the clear off too but it prolongs the time a lot. I buy it in 2 pound bars about 2 inches square and 7 or 8 inches long. Its a cut / color rouge meaning it cleans and polishes in one process.

https://caswellplating.com/black-magic-rouge-grade-a.html