Topic: 1981 XV1000 TR1-project

[DME]

...found a bottom end that I picked up for spares.
The top end parts are easier to find as parts from the XV1100 (Virago) can be used.
The bottom end is more difficult as the XV1100´s are shaft drive and hence uses completely different cases.

Started to disassemble the spare bottom end and found no obvious problems with it.
Also found a paint remover that actually works, so the cases are now paint free and ready for a session in the vapor honing cabinet 

[DME]

First session of vapor honing done on one of the case halves.
Will do the other case half next at the same pressure, and then probably give the both halves another session at lower pressure to really bring out the shine 

[grcamna2]

The case has a nice shine to it.
I prefer that vapor-blasted surface above all others:much more than paint.

[Ellz10]

I agree. I myself am partial to vaporblasting. Can't beat that finish.

[DME]

I guess the fact that i built my own vapor blasting cabinet speaks for itself... yes I´m partial to vaporblasting too 
I find the look to be really nice, not overly "blingy" as a polished surface might look... and the fact that it keeps it´s looks over the years might be the most important thing.
Easy to clean, just a spunge and some soapy water and it´s done 

[grcamna2]

I guess the fact that i built my own vapor blasting cabinet speaks for itself... yes I´m partial to vaporblasting too 
I find the look to be really nice, not overly "blingy" as a polished surface might look... and the fact that it keeps it´s looks over the years might be the most important thing.
Easy to clean, just a spunge and some soapy water and it´s done 

I was reading from a member on here who had a vapor-blasting business;he says the vapor-blasting treatment somehow seals the cast aluminum which retards corrosion in the future.

[DME]

Well yes, the effect is very much alike conventional ball burnishing as the glass beads smoothes out the surface imperfections:
https://www.inovatecmachinery.com/blog/ball-burnishing/
Hence the importance of running low pressure, as high pressure will deteriorate/crush the glass beads faster and the crusched glass will give a rougher finish.

[DME]

Both crankcase halves have now been through their first vapor honing sessions:

[grcamna2]

 

[DME]

Disassembly has begun.
The wiringloom was constructed with the goal to be able to remove it from the bike without the need to disassemble every single connector, and that goal was reached.
Fact is only the tank, seat and upper triple tree must be removed to get the loom off 

[Ellz10]

Disassembly has begun.
The wiringloom was constructed with the goal to be able to remove it from the bike without disassemble every single connector, and that goal was reached.
Fact is only the tank, seat and upper triple tree must be removed to get the loom off 

Now THAT is convenient. Totally awesome!

[DME]

Disassembly of the chassis gets somewhat complicated when the engine is a fully stressed member... but it's getting there 

[BenelliSEI]

Fantastic build. Really enjoying the details.

[MauiK3]

I have shop envy

[DME]

Thanks guys!
Finally the chassis is apart 

[BenelliSEI]

Dan….Today I caught myself staring at my 2008 Honda Varadero XL1000 wondering what it would look like without all the extra road gear. Then I noticed the two, massive radiators….. next I ended up trolling KIJIJI looking for a 1981 Yamaha. Help!

Truly fascinating build. Well done.

[DME]

...next I ended up trolling KIJIJI looking for a 1981 Yamaha. Help!

Down the rabbit hole... 

[grcamna2]

I see everything bolts to the engine/transmission assembly cases(the 'hub' of the motorcycle)on the XV1000 DME 

[DME]

I see everything bolts to the engine/transmission assembly cases(the 'hub' of the motorcycle)on the XV1000 DME 

Well, it does now 
The main frame is slightly modified to make the engine fully stressed.
I wanted to fully test the mods before paint and other surface treatments, hence long test period of just under 10000 km (62500 miles) on all kinds of surfaces.
No ill effects have been noted, the chassis on the build is actually handling a lot better than what the chassis on my stocker does.
The fact that it has lost more than 50 kilos is probably the biggest cause of handling improvement.

Here´s a pic of all the disassembled chassis parts ready for sandblasting:
(swingarm (lightened), subframe (homemade from scratch), front engine mount (stock), swingarm pivot mount (modified) and mainframe (modified))

[DME]

Wanted to get rid of the paint on the stamped framenumber before sandblasting. The stamped numbers looked fairly shallow and I dont want them damaged by the blasting process.

However, the paint remover I used for the engine block wouldn't touch the paint on the frame so I had to get a bit creative...
Mixed a couple of table spoons of lye (caustic soda) in some paint remover, piled the mix on and let it sit for a couple of hours.
Worked like a treat, scraped the paint off with a wooden stick 

The area can now be masked while being blasted, as well as during powdercoating. When its all done I will cover the raw area with a thin coat of protective paint from a spraycan.

[grcamna2]

I like this idea of using paint remover on the identification numbers.
I had a Honda frame powder-coated and should have done this process:the numbers were stamped very shallow from the factory and now,after the PC process,they are very difficult to see. 

[DME]

Visited a friend of mine this weekend who has a big sandblasting cabinet and the compressor to match.
The plan was to spend the time needed to get all the frame parts blasted and ready for powdercoating.
Was working very well and the rear subframe, front motormount and the mount for the swingarm is now blasted.
However, while blasting the frame the coupling between the the electric motor and compressor decided to throw in the towel.
The compressor block is fine and so is the motor, was just the anti-vibrationrubber in the coupling that gave up probably due to age...
Anyway the work was halted and I need to finish the frame and swingarm elsewhere.
To be continued....

[grcamna2]

I'm sure these parts will become very nice when they are coated. 

[MauiK3]

It always comes down to equipment maintenance, gets you every time.

[DME]

Yep, it sure does... but on the other hand it was a good thing that it was just the coupling that failed, would have been far worse with a broken motor or, god forbid, a seized compressor block...