Progress!!! 1978 GS1000E Restoration/Performance Rebuild

[Kiwi Canuck]

Small parts - BACK FROM THE POWDERCOATER!!!

Very nice job on the powder coating, did you tape all the threaded parts or will you need to chase the threads out?

I didn't see the battery box in that batch, did you get it done as well?

Also what is the item in the top left, looks like it's fender related but I don't recognize it.

Cheers,

David

[eil]

This bike is going to look like a million bucks.

Thanks for the detailed write-up on the zinc plating. I have a feeling that's something I'm going to dabble in one day. How long do you expect the plating to hold up against corrosion? (I'm sure it depends a lot on how clean the bike is kept, local humidity, etc.)

Those $60 eBay power supplies work but are known to go kaput after a time. Some fail by delivering high voltage to the output with spectacular results. Not saying yours will but if it were me, I wouldn't leave it unattended for too long. Unfortunately I don't know what the best buy in power supplies is right now because I'm still trying to figure that out myself.

[philosopheriam]

Very nice job on the powder coating, did you tape all the threaded parts or will you need to chase the threads out?

I didn't see the battery box in that batch, did you get it done as well?

Also what is the item in the top left, looks like it's fender related but I don't recognize it.

Cheers,

David

David - my powdercoater may cost a few extra $$$, however, he faces and chases EVERYTHING. Also, his masking, taping is 2nd to none - I rarely have to clean goo out of threaded holes, etc.

The part in the upper left is a metal fender support - I'm going to be running a front fender from a later model 1100E. As for the battery box, it's going to wait until the end because I am still modifying/welding/chopping it to make mounting surfaces for my R/R, main charging fuse, keyswitch fuse, and main fuse. I'm going to be adding 3 relays to the system (horn, ignition coils, and main) and an updated blade-style fuse panel.

[philosopheriam]

This bike is going to look like a million bucks.

Thanks for the detailed write-up on the zinc plating. I have a feeling that's something I'm going to dabble in one day. How long do you expect the plating to hold up against corrosion? (I'm sure it depends a lot on how clean the bike is kept, local humidity, etc.)

Those $60 eBay power supplies work but are known to go kaput after a time. Some fail by delivering high voltage to the output with spectacular results. Not saying yours will but if it were me, I wouldn't leave it unattended for too long. Unfortunately I don't know what the best buy in power supplies is right now because I'm still trying to figure that out myself.

The corrosion resistance of the zinc plating depends on it's thickness - zinc is sacrificial, thus, the more zinc on a part the longer it will hold up before the base metal corrodes. I'm plating my parts for around 20min, which should be between .0005 and .001 of plating. I haven't been measuring before/after of each part with a caliper

As for the power supply - I will keep an eye on it. I only run it for 20min at a time, moreover, I don't run it at maximum, either - 4A, which is 80% of it's maximum current of 5A is the highest I will go. 4A will plate quite a few parts. My biggest batch usually runs around 2.5 to 3A.

With that being said, having a CC rectifier for zinc plating IS the way to go. It removes an element of guesswork from the equation, and it just makes life easier.

[philosopheriam]

More shiny zinc stuff:

IMG_1315 by Anthony Monteleone, on Flickr
IMG_1314 by Anthony Monteleone, on Flickr

[philosopheriam]

This is what you house starts to look like when you are restoring a motorcycle (the loft on the 2nd floor of my house)

IMG_1311 by Anthony Monteleone, on Flickr

[philosopheriam]

I can see the light at the end of the tunnel - MORE PROGRESS! Cylinders, head, and cams installed. Cam timing and buttoning up the remaining parts of the engine to follow.

101 by Anthony Monteleone, on Flickr
11 by Anthony Monteleone, on Flickr
12 by Anthony Monteleone, on Flickr
13 by Anthony Monteleone, on Flickr
14 by Anthony Monteleone, on Flickr
141 by Anthony Monteleone, on Flickr
15 by Anthony Monteleone, on Flickr
16 by Anthony Monteleone, on Flickr
17 by Anthony Monteleone, on Flickr
171 by Anthony Monteleone, on Flickr

[philosopheriam]

Additional photos

1 by Anthony Monteleone, on Flickr
2 by Anthony Monteleone, on Flickr
3 by Anthony Monteleone, on Flickr
5 by Anthony Monteleone, on Flickr
6 by Anthony Monteleone, on Flickr
7 by Anthony Monteleone, on Flickr
8 by Anthony Monteleone, on Flickr
9 by Anthony Monteleone, on Flickr
10 by Anthony Monteleone, on Flickr

[philosopheriam]

And there's more!!!! Who doesn't love more pictures?

172 by Anthony Monteleone, on Flickr
173 by Anthony Monteleone, on Flickr
174 by Anthony Monteleone, on Flickr
18 by Anthony Monteleone, on Flickr
19 by Anthony Monteleone, on Flickr
20 by Anthony Monteleone, on Flickr

[BadBillyB]

Hey, looking good.....Don't forget your cam chain guide (between the cams) and liberal amounts of MOS2 for the cam lobes and adjustment shims......And word of caution, don't install the tach drive until the exhaust cam is bolted in.....Billy

[philosopheriam]

Hey, looking good.....Don't forget your cam chain guide (between the cams) and liberal amounts of MOS2 for the cam lobes and adjustment shims......And word of caution, don't install the tach drive until the exhaust cam is bolted in.....Billy

Thanks Billy! Noted on both the cam guide and break in lube. Also, I had no intention of installing the tach drive until the motor is in the bike.

[rudeman]

Looking good there man! Nice attention to detail.

[philosopheriam]

Looking good there man! Nice attention to detail.

Thank you! For those who are interested, I have a the zinc plating process down fairly well - if anyone wants to try this send me a PM and I will help you get started. My experimentation can save you some $$$ with the initial setup.

[JTGS850GL]

Why not do a DIY write up so others can learn from your hard earned efforts for years.

[philosopheriam]

Why not do a DIY write up so others can learn from your hard earned efforts for years.

Perhaps - a sticky would probably work well. When I have a bit more free time it will be on my list of things to do