Electrics

Started into the fitting of the electrics.
Front end is now complete and the loom
is loosely fitted.

I need to fit the plastic under trays to the
rear frame to determine where the regulator
rectifier etc are to be placed.

I was going to use the rear standard
mud guard, but its getting the chop and will
use an alternative.

Gear Change

Using some more aprilia RS125 parts I was able
to set up the gear change linkage.

Caliper finished

In preparation for the final dry build I
managed to get the front caliper finished.
coated with heat resistant primer covered
with heat and fluid resistant paint.

Im also modifying the bench for the slightly
longer wheelbase and Bram was lending a paw
to the carpentry!

Pipes Welded

I picked up the pipes from the welders on Friday
and test fitted them, Fit perfect!
Next on the list is a big cleanup in the garage
and get the gear change linkage fitted then fit
the electrics and loom.

Pipe ready for Welding

After sourcing a suitable length of pipe with
the correct bore I cut a section with angled ends
to extend the end can of the left pipe to clear the
swingarm. The end can will be extended by about
70mm. The original internal stinger has been cut
to be welded in place where it would normally be
with the other end with the silencer being able to
fit back into the end can. The stabilizer strap will
have to be remade to span across the 3 sections
of pipe.

The images below show the pipes taped up to give
an impression of the layout/run of the pipe. [its a bit saggy!]

New seals

Finally sorted the dust seals for the front forks out.
Cardiff Motorcycles via E-bay sent a different set
even though I had bought the originals about 2 months
ago. So first fork finished today with the other draining
overnight.

Exhaust run

I made a start today about stripping the frame totally while
the front end was off. I flipped the frame and installed the
engine cases with the barrels and heads in order to finalise
a solution for the left side exhaust pipe. I think I have
sourced a suitable bit of mild steel pipe to extend the
silencer past the swingarm.

Front Caliper Strip

The aprilia front brake caliper needed a refurb so
I stripped the paint and is now ready for a new coat.
The pistons and seals are still good so they will be
going back in.

Rear Brake Caliper

Finally finished the rear brake caliper bracket.
I an using a Honda Varadero 125 Rear wheel
so the bracket and caliper are matching.
There is an extra wedge shape welded to the
bottom to match up with the Yamaha YZF-R125
swingarm.

Party Pooper

I decided to attack the forks yesterday and started
with the right side disassembly, I drained the oil and left
the tube standing up side down overnight.

I went to fit the seals tonight and the dust seal is not
the right size, what a pain.

Fork Refurb Kit

Fork seals and Oil ready to go along with some
Super Glue to apply to a small rust spot chrome
of the left leg.

I have both 10w and 15w fork oil so I think I will
run with the 15w for stiffer damping.

Clocks Refurb

The original RD250 clocks I have needed a bit of fresh
coating. The buckets have been sprayed black and along
with the main bracket have been clear coated.
All nuts and bolts have been replaced with Stainless Steel
and some copper grease to help with future removal.

Because the weather has been terrible lately we have been using our
central heating, perfect for the freshly painted fork bottoms.

Headlight Finished

After plastic welding, filling, sanding, spraying and baking
the headlight is finally re-assembled with replacement
stainless steel fittings.

I coated the back side of the reflector and located a new
H4 bulb retaining spring. The inside has been cleaned
and is now very bling. The chrome ring on the outside
is still showing some rust spots, will probably spray
it a brushed aluminium finish some time later.

Plastic Welded

After about 4 hours of breathing through a 3M
mask I finally got the headlight bucket welded
and sanded back. The remainder of the bucket
can now be sanded to accept a primer and then
finished in Black.

I laid down 2 flat panels to the inside of the bucket
as a base to start filling with melted ABS.

Plastic Welding Kit

I plan on welding some ABS plastic I have been saving
to patch up the headlight bucket.

Did a bit of a trial run last night and a good quality
mask is definitely needed, the fumes from melting/burning
ABS Plastic is not good.

Olympic Headlight Task

I have this 7" Headlight knocking around the garage for a while and is
showing signs previous campaigns. the bucket has a piece missing and
some cracks at the mounting holes.  There has also been a piece cut out
of the back i assume to allow more cables in/out or for easier access,
im not sure. The glass is marked Stanley and needs a clean as does the
reflector.

The plan is to block up the part that was cut out to leave the small access
point for cables and bulb and seal the cracks.

Here it is disassembled.

Switches

Over the last couple of weeks i have been working
mostly in the garden with a bit here and there in the
garage working on the front end of the project.
Both RD250 original handlebar switches have been
stripped cleaned, sprayed and assembled with stainless
screws/bolts and the wires re-covered with fresh heat shrink.

A bracket has been fabricated from 3mm aluminium bar
and fixed to the brake lever assembly.

I have also sprayed the clock backs and bracket along with
the headlight brackets, more on that to follow later.

Yokes Finished

Got the top and bottom yokes finished.
Drag bars fitted to the top yoke with alloy risers
and stops fitted to the bottom yoke.