Oil Tank Repair

Another task today was to repair the oil tank, the outlet nozzle was cracked where it joined the main body of the tank.

Whoever repaired it before used a kind of resin which was leaking, I removed the resin, cleaned the area with brake fluid and "welded" some plastic into the area to seal it. I used a sliver of plastic from a coolant overflow tank, which obviously wont be using and melted that with a soldering iron!

 

While welding the area I left a screwdriver stuck in the nozzle so that the area would retain its normal shape and not deform with the heat.

The job is perfect, I tested it for a water leak over a few hours and it aint leaking!!

 

 

Rear Wheel Fitting & More Front End

Fitted the rear wheel today along with the front bars, controls, Clocks and headlight shell.

Front and Rear Suspension fitted

After having to make 2 Aluminium spacers for the lower rear shock mount, parts were cleaned and greased and fitted to the frame.

I have some round Aluminium bar which I have been making spacers from with basic hand tools. First I mark the desired width with a pipe cutter and with a junior hack saw I cut a little at a time along the score mark rotating all the time to get a straight cut.

Painting Parts

For the last few days I have been prepping parts for painting, Satin Black is the finish, It goes better than gloss than my painting skills.
Parts painted:
Engine mount brackets
Taillight bracket
Seat Latches
Kickstart
Rear Master Cylinder
Brake pedal
Rear Caliper Carrier
Swing arm spindle [ends]
Gear Change Rod

Swingarm - 1 week & 20 hours later

A bit dissapointed after inspecting 20 hours of sanding and polishing the swingarm in the sunlight, not enough sanding from rough to fine.

Swingarm - Removal of Orange Peel

This swingarm was never intended to be polished, the finish is very uneven, Yamaha decided it would be best to have a "Matt" finish as a cost saving approach. I decided I would remove the orange peel effect and polish it up.....

After approximately 8 hours over 2 days I have it ready for polishing. I started with a 3M scotch disc followed by 60, 80, 120, 240, 360 grit sanding discs, then 400 and 800 grit wet sand paper, (i have some 1200 wet and dry paper, I might give it the once over with that too)

Swingarm Finish

I need to figure out how to finish the swingarm, strip and polish or repaint?

Frame Painted

Frame painting finished tonight, 7 to 8 coats of 2K Signal Black RAL9004 Satin,

very happy with the result, no paint runs!

Frame Prep

Frame sanded and completely painted with "Oxirite" rust converter before the 2K paint.

Group Shot

Ahead of what will hopefully be the final build is a shot of almost all the parts ready for cleaning, coating and assembly.