81 GS550T Full Rebuild...In Ohio

[cowboyup3371]

Thanks Tom I just didn't know if I could bake them tomorrow or if I had to wait until next week since the can didn't say. And yes, it was Duplicolor's Brake Caliper paint

[tkent02]

Thanks Tom I just didn't know if I could bake them tomorrow or if I had to wait until next week since the can didn't say. And yes, it was Duplicolor's Brake Caliper paint

I'd start with low heat and after a while turn it up to what is recomended on the can.
You got an outdoor oven of some sort or are you going to be breathing this **** all night?

[cowboyup3371]

I have a toaster oven at the garage now. Bought it for 5 bucks last year from a college kid

[tkent02]

Perfect .

[cowboyup3371]

After realizing the 3/8" spacer just wasn't going to play nice for me, Steve offered to grind down the spacer from Gustovh. A couple of attempts at it and a little "persuasion" while installing it finally got everything in place like it should. I then ensured all bolts were able to be put into place and so I'm able to torque them tomorrow evening.

I didn't throw the rear caliper into the oven yet but it sure looks good (sorry, still no pictures). I also wiped the fronts down with acetone, painted them, and then cleaned the airbox so I can repaint it. As I have rear brake parts coming in Wednesday I hope I can start finishing up the main chassis stuff by this weekend. Then we'll prime the tank, side covers, and wheels with painting to follow soon....or at least that's the plan.

I think that last statement is what's really bothered me about this project since late March - every time I think I am going to be close to finishing, something comes up with work or parts and I fall behind again. I am so ready to be done and riding before the season ends it hurts.

[pete]

I hear ya' Scott, you get to that point where you can see the light and then the little things crop up and it's so frustrating!

However, you're making excellent progress, so chin up and you'll be there before you know it

[cowboyup3371]

After playing band dad on Saturday and helping out with school work on Sunday, I finally had a chance to go work on the bike by leaving pretty early this morning. First things first, I cleaned up the airbox and battery box then hung them to dry until the humidity could fall back to a more reasonable level. While that happened, I grabbed the brakes and my side covers to take back to the house. Brakes were finally put back together with the fronts fully done:




While the rears were halfway finished at the house. It seems I forgot to clean out the mounting bolts and had left the cleaning stuff back at the garage. Plus, I ordered new brake pads from Z1 on Friday and should see them by tomorrow. But at least they went back together fairly easily and once I returned to the garage later in the day, I cleaned up the bolt heads with the roloc pad.



I also painted the battery box and airbox (metal bits) then headed for home for dinner.

Once dinner was done, the eldest and I ran back to the garage where she helped clean up the brake rotors so I can tape them off to paint later this week. While she did that, i put the airbox back together and mounted the battery box with new rubber grommets and washers to better fit it this time.

Then the real fun began. I thought I'd have an easy time with this as the carbs slid right into the airbox boots without a second thought. I tightened them down and started to mount them into the intake when lo and behold the carbs and airbox boots parted ways. So much for a non-cursing night. I finally mounted everything much like I remembered them last year but I still don't like the looks. Yes, they are stock boots all the way around but something just doesn't look right. I'll have another go at them tomorrow when it's a bit earlier in the evening.




But here's how the bike's looking right now.

[pete]

Excellent Scott, looking good! Those calipers look the goods

You're right on the carbs though, they're definitely not sitting right in the intake boots.

I assume they'll be like mine where there is a lip on the inside of the intake boot that needs to sit in the groove on the outside of the carb mouth.

I can see the groove is still outside the intake boots in that photo which is what's telling me they're not seated correctly.

[cowboyup3371]

Some lubrication and they slid right in...should have thought about that Monday but it was too late. Tonight, I was going to use marine grease but was told to use WD-40 instead...thanks again to the master mechanic on the forum.

[Steve]

...thanks again to the master mechanic on the forum.

Some day, I am going to meet that guy.

.

[pete]

Hahahaha trust you Steve

Just FYI I used rubber grease on mine before I put the nice new soft ones on...

[cowboyup3371]

After picking up the base and clear coats from the local paint shop, I finally finished redoing the bondo on the gas tank while the eldest cleaned off the residue from stripping the wheels. So, we're going to lay down the primer in the AM then see about painting next weekend.

Also replaced a couple of terminals on the wiring harness and will try to get it back on the bike tomorrow.

[cowboyup3371]

Parts are primed and I'll go sand down the tank later this afternoon. Hope to lay down the base coat Friday night or Saturday morning then the clear the next day.










I will admit to this...painting with a gun is nowhere near as easy as it looks especially since I'm real bad at judging distance when looking at things. My friend had to step in on more than a few occasions to get spots I missed or tell me to slow down.

Oh well, I'm looking forward to seeing the final product.

[pete]

Good stuff Scott, I'm so jealous of the room you have!

Painting with the gun definitely takes some practise. I think I was starting to get the hang of it by the time I got half way through the clear coat... the primer was ok but spraying the pearl base coat was an adventure, not sure if you remember my first effort ending up mottled and I had to sand it back and start again.

Well worth the end result though

[tkent02]

My friend had to step in on more than a few occasions to get spots I missed or tell me to slow down.

Scott, slow down!

Are you absolutely sure the prep is perfect? Can't see the bondo even though you know where to look? No flaws, stains or fingerprints on it anywhere? No funny textures or discolored spots?

Is your friend going to be there while you shoot the rest of it? Got any old appliances or fenders mailboxes or anything you can practice on?

Can't wait to see the end result.