Progress!!! 1978 GS1000E Restoration/Performance Rebuild

[blowerbike]

1000's dont have the piano wire deal.
i would try the 1000 inner hub 1st.
1000 steels and fibers are larger OD than 1100's but less plates.
1100's have 9 and 9 including the one behind the piano wire but are smaller diameter.

[Arronduke]

Engine paint and mods looks the dogs bullock as do the rims.

Just to put me correct, that's powder coating on top of powder coating? if so I did not know that could be done.
Was the clear also powder coating?

Dam impressive!
(green monster - envy going hard)

[philosopheriam]

Engine paint and mods looks the dogs bullock as do the rims.

Just to put me correct, that's powder coating on top of powder coating? if so I did not know that could be done.
Was the clear also powder coating?

Dam impressive!
(green monster - envy going hard)

All of the colors on the wheels are powdercoat - speedway black, silver, and clear. Each color is laid down one at a time and cured before the next is applied. And yes, there is such a thing as clear powder :-)

[philosopheriam]

Two coats primer:

IMG_1077 by Anthony Monteleone, on Flickr
IMG_1075 by Anthony Monteleone, on Flickr
IMG_1076 by Anthony Monteleone, on Flickr

IMG_1078 by Anthony Monteleone, on Flickr

IMG_1079 by Anthony Monteleone, on Flickr

IMG_1080 by Anthony Monteleone, on Flickr

[philosopheriam]

Three coats VHT universal aluminum:

IMG_1083 by Anthony Monteleone, on Flickr
IMG_1082 by Anthony Monteleone, on Flickr
IMG_1081 by Anthony Monteleone, on Flickr

IMG_1086 by Anthony Monteleone, on Flickr

IMG_1084 by Anthony Monteleone, on Flickr

IMG_1085 by Anthony Monteleone, on Flickr

[Big T]

Beautiful work Ian


Are you Ok with the oil filter cover off a 79?

The 78 has a drain bolt

[philosopheriam]

Beautiful work Ian


Are you Ok with the oil filter cover off a 79?

The 78 has a drain bolt

The name is Anthony, but thanks for the compliment, sir :-)

As for the oil filter cover, there are a few things on my motor that don't match up exactly with the 78 parts fiche - the oils filter cover is one of them. The 78 GS1000 hit the American market in February of 78 and my bike is an April model. So, I have an early motor with a few quirks....

[philosopheriam]

Polished Parts

Step 1: Hard wheel with black/hard-cut compound
Step 2: Stitched buff w/red compound
Step 3: Loose buff w/green compound
Step 4: Hand polish with MAAS polishing compound (in French Lavender, ooh la la!!!)

polishedparts by Anthony Monteleone, on Flickr

[philosopheriam]

Head Work: compliments of Ray Rains (rapidray)

Specifications:
APE stainless oversize 1-pc valves, 2mm on intake, 1mm on exhaust
Bronze valve guides
Custom-grind WEB cams
APE viton stem seals
High-performance valve springs (not sure which brand, ask Ray)
Radius valve job
Exhaust & intake ported
Deck surface milled

Exhaust Ports
IMG_1091 by Anthony Monteleone, on Flickr
IMG_1094 by Anthony Monteleone, on Flickr

Intake Ports
IMG_1097 by Anthony Monteleone, on Flickr
IMG_1098 by Anthony Monteleone, on Flickr

Valves & Deck Surface
IMG_1095 by Anthony Monteleone, on Flickr

[philosopheriam]

Spark plug hole repair (compliments of Micron Engine & Machine, Stone Park IL)

Someone stacked x3 Heli-Coils in the #2 spark plug hole . On aluminum heads, I'm not a fan of Heli-Coils as a repair for blown out spark plug threads because they are made of stainless steel and thus they are a poor material for heat transfer - aluminum will draw more heat out of the plug. Also, Heli-Coils can sometimes walk out of place.

The preferred option - a keyed aluminum insert, in this instance I used a Full-Torque branded insert. These inserts are the only ones approved by Ford for repair on damaged spark plug threads in 4.6 and 5.4 engines.

IMG_1096 by Anthony Monteleone, on Flickr
IMG_1099 by Anthony Monteleone, on Flickr

[rapidray]

Anthony, PLEASE make sure you get the manifolds lined up correctly when you re-install them. I know you know this but just wanted to stress it again. Your work looks AWESOME & I can't wait to hear how it runs. Make sure you call me when you are ready to degree the cams so I can walk you thru checking the piston to valve clearance. GREAT job you are doing!!
Ray.

[philosopheriam]

Anthony, PLEASE make sure you get the manifolds lined up correctly when you re-install them. I know you know this but just wanted to stress it again. Your work looks AWESOME & I can't wait to hear how it runs. Make sure you call me when you are ready to degree the cams so I can walk you thru checking the piston to valve clearance. GREAT job you are doing!!
Ray.

Ray,

When I removed the manifolds, I marked their orientation and cylinder # - however, with the shoulder bolts that I used, the manifold lines up damn near perfect once you install it. You only get +- .5mm of wiggle room once the manifold is on the shoulder of the bolts.

[philosopheriam]

Sorry I haven't posted some updates in awhile - the engine reassembly has begun!

In no particular order:
IMG_1138 by Anthony Monteleone, on Flickr

IMG_1142 by Anthony Monteleone, on Flickr

IMG_1149 by Anthony Monteleone, on Flickr

IMG_1145 by Anthony Monteleone, on Flickr

IMG_1144 by Anthony Monteleone, on Flickr

IMG_1148 by Anthony Monteleone, on Flickr

IMG_1146 by Anthony Monteleone, on Flickr

[philosopheriam]

More progress:

IMG_1139 by Anthony Monteleone, on Flickr

IMG_1147 by Anthony Monteleone, on Flickr

IMG_1150 by Anthony Monteleone, on Flickr

IMG_1141 by Anthony Monteleone, on Flickr

IMG_1140 by Anthony Monteleone, on Flickr

[first timer]

Where did you source the lower end case studs? I was under the impression APE only made 16v studs but I haven't taken the time to compare 8v to 16v studs