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Old 06-27-2010, 04:51 PM   #31
melville OP
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I think I'm done polishing for this build. Finished the caliper and clutch lever today. I was going to paint the caliper, bought the paint and even applied it but it looked like dookie. Had to sand it off and work the caliper even more, as the casting pits that would have been filled by paint had to come out. All identifying marks are gone--ATE can reasonably deny involvement.

I was unhappy with the tool marks on the casting part line:





But once I started in on that, what remained of the OG paint acted as a guide coat showing me other flaws:



Where it stood before I painted it:



After removing the paint and getting the remaining casting pits out:



And finally polished, with its buddies the levers and throttle cover:

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Call me Mel. Some years ago- never mind how long precisely- having little or no money in my purse, and nothing particular to interest me at home, I thought I would ride about a little and see the other parts of the world. It is a way I have of driving off the spleen and regulating the circulation.
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Old 06-27-2010, 05:32 PM   #32
Lornce
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Old 06-28-2010, 08:41 AM   #33
blaine.hale
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Are you building a Harley?


Just messing. I'm definitely following this build :)
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Old 06-28-2010, 08:44 AM   #34
melville OP
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Quote:
Originally Posted by blaine.hale
Are you building a Harley?


Just messing. I'm definitely following this build :)
No chrome--just the alu speaking up.

Why do HD riders like chrome?


































Makes it easier to find the parts when they fall off.
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Call me Mel. Some years ago- never mind how long precisely- having little or no money in my purse, and nothing particular to interest me at home, I thought I would ride about a little and see the other parts of the world. It is a way I have of driving off the spleen and regulating the circulation.
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Old 07-08-2010, 08:35 PM   #35
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On to the cast pieces that aren't getting polished. There was much crustiness:











The pieces were degreased where necessary and scrubbed with ScotchBrite #3 or similar steel wool as necessary, then cheap rattlecan alu casting paint was applied with a ScotchBrite pad. This pic shows the front cover post paint, and the clamshell pre and post scrubbing:



And more of the same, finished:





The motor is in the cleaning stages at present. It will also get new PR tube seals and the cylinder bases resealed:

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Call me Mel. Some years ago- never mind how long precisely- having little or no money in my purse, and nothing particular to interest me at home, I thought I would ride about a little and see the other parts of the world. It is a way I have of driving off the spleen and regulating the circulation.
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Old 07-09-2010, 12:17 AM   #36
Padmei
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I have to do this to my new to me R80. The engine looks in very similar condition. The ali paint you talk of -is it just ali coloured paint or a treatment?

Good work so far
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Old 07-09-2010, 01:57 AM   #37
Overdog
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You may need to re-jet the carbs in order to use those short pipes!


.....great job on the build so far!
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Old 07-09-2010, 04:24 AM   #38
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Quote:
Originally Posted by Padmei
I have to do this to my new to me R80. The engine looks in very similar condition. The ali paint you talk of -is it just ali coloured paint or a treatment?

Good work so far
Just a $5.95 DupliColor rattlecan bought at my FLAPS. Color is "Cast Al" or somesuch. Applying it with the ScotchBrite lets the paint fill the pores and leaves the metal on the high spots. Technique courtesy of "The Mechanic from Hell."
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Call me Mel. Some years ago- never mind how long precisely- having little or no money in my purse, and nothing particular to interest me at home, I thought I would ride about a little and see the other parts of the world. It is a way I have of driving off the spleen and regulating the circulation.
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Old 07-09-2010, 05:47 AM   #39
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Nice work Melville
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Old 07-09-2010, 09:46 AM   #40
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Looks great. Are going to call it "Ishmael" when you're done? Please say yes.
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Old 07-09-2010, 10:20 AM   #41
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Quote:
Originally Posted by drhach
Looks great. Are going to call it "Ishmael" when you're done? Please say yes.
Name of the bike is in the thread title. My sons and I agreed on "Ernst" to honor Ernst Henne.
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Call me Mel. Some years ago- never mind how long precisely- having little or no money in my purse, and nothing particular to interest me at home, I thought I would ride about a little and see the other parts of the world. It is a way I have of driving off the spleen and regulating the circulation.
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Old 07-09-2010, 03:38 PM   #42
jsullivan
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This is quickly becoming one of my favorite build threads here. Keep it coming!
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Old 07-09-2010, 07:13 PM   #43
bpeckm
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Quote:
Originally Posted by drhach
Looks great. Are going to call it "Ishmael" when you're done? Please say yes.

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Old 07-09-2010, 08:05 PM   #44
drhach
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Quote:
Originally Posted by melville
Name of the bike is in the thread title. My sons and I agreed on "Ernst" to honor Ernst Henne.
Faie enough. Maybe the next one.
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Old 07-10-2010, 07:08 PM   #45
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So getting the left side clean. This is a "metal finishing" ScotchBrite:



A different technique for the tight spots:



The remains of the exhaust were in the way. It isn't REALLY a project until the Sawzall comes out, in this case to cut the exhaust nut fins, so I could get good access with the dremel and a cut-off wheel. Threads were in surprisingly good shape:



And after I got through most of the cleaning:



Hopefully I'll get to the right side tomorrow.
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Call me Mel. Some years ago- never mind how long precisely- having little or no money in my purse, and nothing particular to interest me at home, I thought I would ride about a little and see the other parts of the world. It is a way I have of driving off the spleen and regulating the circulation.

melville screwed with this post 08-12-2011 at 03:53 PM
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