Mislaid

After fitting the left hand hanger and gear change mechanism I moved on to the right hand hanger to start assembling and realised I misplaced the master cylinder plunger. I remember cleaning it and painting it and I vaguely remember putting it "somewhere safe" so that i'll "find it when I need it". Spent about 45 minutes searching for it.
I also need to find a home for two alternator earth cables, in the workshop manual it says to bolt them to the engine and shows a small image of the location but it does not correspond to this engine?

Spaghetti

Still working on the electrics and the various bolt on bits and pieces that accompany the task.

Adding on

Got a good bit done over the last few days adding on the bits and bobs. Got the handle bars, switch gear and lever housings on. Got the rad and battery box subframe in and at the back end the rear light and splash guards along with the oil tank. I then attached the electronics and rear part of the wiring loom. Its coming together a bit more but looking messy too!

Semi Rolling

. . . meaning there's 1 wheel! Forks and front wheel fitted. All stainless steel bolts fitted and new bearings in the front wheel. I refitted the original brake disc as its within the service limit. The rear subframe has 3 coats of black paint on too to try and keep the rust at bay. The wheels have also been painted the original black by an auto body repair shop.

Here is a link to the before post > http://2strokelover.blogspot.com/2011/12/skeleton.html

From the ground up

Spent a while this evening cleaning and tidying the working space to start the bike rebuild. I got the engine mounted into the frame, swingarm and rear suspension - all the mounting bolts have yet to be tightened and the originals have been replaced with stainless steel where possible.

Bling Bling #1

After approximately 18 hours of sanding and polishing the frame is finally at a stage that I am happy with. With more time and effort the result could have been better but I was just not willing to put that into it.

I started with a rough 180 grade paper on a sanding mouse to get the heavy pitting out, I then moved onto a finer 240 grade on the mouse and some hand sanding. From there I used the wet and dry paper starting with 400 grade through 800, 1000 and finishing with 2000.
After the sanding I attacked the frame with polishing mops, course and medium. I started off with the cutting compound and ended with autosol paste. Pitting can still be seen and some fine sanding marks but again I gave it enough time at 18 hours. It is a big change from the state it was in at the start.

Just to finish off I coated it with ACF50 which dulls the metal slightly.

These images were taken with a Canon 7D and Sigma 12-24.

Buckets of Elbow Grease

. . . is whats needed for the next task, removing the corrosion and pitting of the alloy frame, Swingarm, Bottom Yoke, Hangers and various brackets.

I decided to do a quick [2 hours] test on a section of the frame. I started out with some wet and dry sandpaper [dont know the grade] to cut back some of the pitting. I then used a polishing kit consisting of 3 discs and 2 grades of paste. I started with the rough disc on the electric drill and finished with the medium disc and a final polish with some elbow grease and a clean rag.

After 2 hours of hard graft the pitting is still visible but the corrosion has been completely removed and this section of the frame looks a little healthier.

Pieces

I got the frame, forks and swingarm broken down tonight after removing the rear brake system and wiring loom. The tedious task now begins of cleaning these and then polishing them to start the rebuild.

Skeleton

Well Its almost there, Just have to get the engine out and then I can start breaking the frame.