Rons' 78 GS1000 rebuild

[1978GS750E]

Went to install the right handlebar switches today and found this.
IMG_0357.jpg

I know that I ordered new throttle cables, but cannot find them anywhere.

Or...…..it could be my oldtimerz kicking in again! Anyway, they won't be needed for a while! Just added them to the ever-growing list.

[1978GS750E]

Got the wiring harness routed correctly and installed the headlight bucket and headlight.
IMG_0358.jpg

[SusKatCas]

Very nice work.

What are you using to re-zinc the hardware?

Thanks, Alan

[1978GS750E]

I started with the Caswell plating system, then after 2 failed batches of solution, I started using a homemade plating solution. You have to do more polishing, but you can make a batch for about $10 instead of the $70 that Caswell charges. So far, I am happy with the results.

[1978GS750E]

Got the cylinders and head back on the engine today. Tomorrow is engine cleaning day! (Oh what fun that will be!) Still have to re-install the cams. Hope to have it complete, painted and installed in a couple of weeks.

[1978GS750E]

Got the coils cleaned up and installed this morning.

IMG_0359.jpg

Now on to the engine cleaning!

[1978GS750E]

Got the engine cleaned up and painted this afternoon.

IMG_0362.jpg


Now to get it in the frame!

[steve murdoch]

Looks very nice.
Also looks very nice to see a pic outside and not have snow in the background.

[1978GS750E]

Got the engine sitting in the frame tonight!
IMG_0370.jpg

Man that thing is a heavy lump! But at least I'm making progress.....slow progress, but progress nonetheless!

[unfocused]

Got the engine sitting in the frame tonight!
[ATTACH=CONFIG]60390[/ATTACH]

Man that thing is a heavy lump! But at least I'm making progress.....slow progress, but progress nonetheless!

You should try to stuff that mill into a 750 frame. I did and ugh. LOL

[limeex2]

I started with the Caswell plating system, then after 2 failed batches of solution, I started using a homemade plating solution. You have to do more polishing, but you can make a batch for about $10 instead of the $70 that Caswell charges. So far, I am happy with the results.

Between personal and parental health issues, I'm back to where I was stuck over 2 years ago. Plating. I need a recipe for plating. I'm not the brightest bulb on the tree for learning new processes so I cant seem to follow the threads that have been posted here. can you help us? Sorry for interrupting your thread, your bike looks great!

[1978GS750E]

Got a little more done today. Got the cams installed, valves adjusted, timing chain tensioner, engine mounts, electric panel, chain, sprocket cover, case savers, throttle cables, airbox and those $#%^&*carbs installed!

IMG_0371.jpg

Still have lots of cases to polish. Looks like a new clutch is on the agenda for this week.

It's finally starting to look like a motorcycle again!

[1978GS750E]

Got the clutch plates installed this afternoon and the cover back on. Decided since I had a little more time, to install the factory exhaust that I purchased. Started with the right side and for the life of me, could not get the flange to go "easily" onto the studs that I installed. After about 15 minutes of using some very colorful language, and right before reaching for the BFH I found this.....
IMG_0374.jpg

I guess someone at the plant in January of 1978 wasn't paying a lot of attention when this one was drilled! Opened the holes up about a 1/16" and it went on like buttah!

[1978GS750E]

After the exhaust flange fiasco was solved...…..
IMG_0375.jpg

[uk gs nut]

Looking good !.I had same issue with exhaust collar and did the same as you.