Front Brakes Fitted

Small update while waiting for parts, I fitted a different Aprilia front caliper as I didnt feel the red didnt suit the dull gold of the rear. I made up a new Goodridge braided line with stainless banjos.

Got the reservoir relocated for a better pipe connection to the master cylinder.

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!

Rear Caliper Masking

Before masking off the joining surfaces of the 2 halves I decided to check out the pistons to make sure they were still ok . . .and sure enough with aid of an old brake line and a bicycle pump the pistons popped out and they are great, no rust or marks on the surfaces and the internals of the caliper are like new, great I can now go ahead and recover the caliper in the original bright red finish.

What lies beneath

After polishing the hell out of the Frame, Swing Arm & Hangers [Images to follow] I made a start on the rear wheel. I have the old Tyre off and attempted to remove the brake disc, to no avail. 2 of the studs are corroded in place. 3 of the 5 I removed with an Impact driver but the driver has just damaged the allen head of the studs.

There is also a lot of work ahead in stripping the paint from the wheel and removing the corrosion underneath and then recovering . . . and the same with the front also.

Heavy Corrosion

Here is the second batch of images before the clothes are stripped.

There is a lot of corrosion to all the metals and some general observations below.

1.] the chain and sprockets need to be replaced, I was going to clean the chain in Kerosene but its too far gone.
2.] the rear shock is leaking and heavily corroded.
3.] the l/h gearchange and footpeg hanger seems to have been bent.
4.] the brake discs dont seem to be too bad, although the brake surfaces are rusted they are not
heavily worn
5.] the brake hoses seem good but we would be looking at changing them for braided lines.
6.] almost every nut and bolt while originally being galvanized or coated in some way have been attacked by rust to the plan is to replace them all with stainless steel.