Topic: Project "Hard Luck - The Red Racer" - updated 07/30/2010 w/new project!!!

[KB02]

The Good:
The rear brake is finally sorted out and has a good feel to it (as best as I can feel it anyway - see the bad below)
The nasty paint on the forks has been removed.
The fork seals have been replaced.

The Bad:
The starter problem is not only not fixed, it seems to be worse.
Something is wrong with the kick starter (might require, yet again another pulling of the engine to find out whats wrong).
The forks are simply sitting is bare aluminum.
The right fork will need to be replaced.
It won't start.

One step forward, two steps back. 

I'll run you though my day:
For Christmas, my father-in-law got me a nice new bench grinder. I figured that my old one, which stunk as a grinder, would make a nice buffing wheel. I bought the buffing stuff that I needed, but the old grinder is so bad, that I doesn't even have enough torque to load up the cloth with buffing compound. So, after I had gotten all of the paint off of the fork lowers, they are not going to sit that way until I figure out a different plan.
Then I was onto re-assembling the forks. Looking the Clymers Manual I had for the Katana for directions: The oil seal has to be put in place with the forks together. The recommended method is by using a seal driver. It does say, though, that you can use a drift punch and hammer - just be careful. DO NOT - DO NOT - DO NOT LISTEN TO THESE STUPID INSTRUCTIONS FROM THESE STUPID M%^#@^ F#%*@$'S. I now have beautiful scores on the down tubes that will most likely cut into, and thus ruin, the brand new fork seals. I did my best to file them down, but who knows how well I did. Look like a new fork in my future. The only good part in all this is that it looks like this fork had been taken apart before and not put back together right. I had to do some repairs while I was in there. THEN - while filling the forks back up with oil, I forgot to put the bottom bolt back in. All kind of oil on the floor... 
Got the forks back together. Got the front wheel back on. Got the rear brakes all sorted out (the one good thing that happened).
When to start and the starter just spun. No Love. Tried kicking it, the kicker started to skip and not return all the way if it returned at all. Tried push starting it (getting desperate) and got nothing but a few sputters.
Gave up for the day...

I had planned on going through the front brakes, too, but the way the day progresses, I'm leaving those for another day. My next day off is in about a week and half. At least it is getting warmer out and I can venture out in the garage without getting too cold. Now if I can only get the lighting in my garage to work better (neon light - wont come on) I could work after dark at least.

[HedNut]

You gotta watch out!!....the world is full of those STUPID M%^#@^ F#%*@$'S!! as you so eliquently put it. 
I'm sad to hear about your starter, kick'r and fork'n issues...I feel your pain...and really hope you don't have to dive right into the cases again.   May the SOHC gods be with you!!!
Here's hoping everything else goes smoothly!!!
Cheers!!!

[Laminar]

THEN - while filling the forks back up with oil, I forgot to put the bottom bolt back in. All kind of oil on the floor... 

You're not alone. I managed to do that not once but twice while rebuilding my forks this week. 

[HavocTurbo]

If you want to borrow an adjustable one.... seal driver.... I have one.

Or if you measure the fork diameter I can send you one fit just for your forks.

[KB02]

I went to the local auto parts store and bought a length of exhaust that was just the perfect size. 1-3/4" ID pipe with a female side on one end. Couldn't have been a more perfect fit for a seal driver.

Next chance I get I am planning on pulling the starter itself and really diving into it. Hopefully it isn't a starter clutch issue (850 kit shouldn't cause THAT much compression) and it's just the starter itself. We'll see.

My Dad is working on the dash this weekend and I still have the front brakes to go through, so I have a few things I can fiddle with while I let myself calm down.

[KB02]

Got the dash plate finished... er... well... my DAD got the dash plate finished. Now I've got to get it polished up and mounted to the bike.

[KB02]

Okay, it's been a while. But I finally have something to update on. After a long time coming, I have finally started in on the paint!!! When I bought my paint supplies, the guy at the store did not want to sell me the paint. At first he tried to convince me to have someone else paint it for me. Once he kind of saw that I wasn't going to back down, he was very helpful in getting me just what I wanted and needed to get it painted right. A stop by the hardware store later and I had the plastic I needed to build a paint booth in my garage.

I sanded down the side covers (after fixing a crack on two of the attachment pegs and gluing the third one back on) and the front fender. The seat pan come ready to paint (or so they said). And a primer has been applied. Next step will be to strip the old paint off of the tank and then to prime that. I pretty sure I have some old paint floating around somewhere that I will practice with my new spray gun. I'll grab the tank from my donor Katana and see what I can make work there. Then I will be into the real paint on the real parts.

I've gotten so used to seeing this bike in black and gray it's going to be really weird seeing it in it's actual color.

[HedNut]

Can't wait to see it!  Cheers!

[leogriss]

You sure it's not machine welded? 
Looks amazing!

May I ask what Kind of paint was used for the engine? Love that color scheme!!

[KB02]

The man is an artist, what can I say? (And a hell of a nice guy, too!)

As for the engine paint, I went to the local auto parts store and bought regular engine enamel in a rattle can. I'll see if I can find the can at home to post exactly what brand it is.

[pampadori]

Okay, it's been a while. But I finally have something to update on. After a long time coming, I have finally started in on the paint!!! When I bought my paint supplies, the guy at the store did not want to sell me the paint. At first he tried to convince me to have someone else paint it for me. Once he kind of saw that I wasn't going to back down, he was very helpful in getting me just what I wanted and needed to get it painted right. A stop by the hardware store later and I had the plastic I needed to build a paint booth in my garage.

I sanded down the side covers (after fixing a crack on two of the attachment pegs and gluing the third one back on) and the front fender. The seat pan come ready to paint (or so they said). And a primer has been applied. Next step will be to strip the old paint off of the tank and then to prime that. I pretty sure I have some old paint floating around somewhere that I will practice with my new spray gun. I'll grab the tank from my donor Katana and see what I can make work there. Then I will be into the real paint on the real parts.

I've gotten so used to seeing this bike in black and gray it's going to be really weird seeing it in it's actual color.

Paint booth? i paint in my dirty old workshop.  Turn of the air, close the windows and spray the floor down with water as to not stir up the dust. 
Use "heavy build" primer in the rattle can.  Its about $4 a can and you'll need two.  THe modern clear coat and activator from Transtar is really good.  GOes on thick and hides every imperfection very well without running. 

[KB02]

Well, I got my paint booth up (Workshop shares a not-too-well-sealed wall with the house - need to booth to keep the fumes to a minimum).


Side covers before primer:


And a few things after primer:



Need to do some more sanding (funny how a nice coat of paint can point out the imperfections), but it's a good start.
The tank will need to be stripped:




This will be at least the fourth paint job for this tank. It started out brown. Had what looks like a nice paint job to blue. Then it got painted black. I'm going with red cause it's faster. 

In between all of this I have been working on this project as well:

[KB02]

After a second round of paint stripper:


Clearly this tank has been painted before and they covered up a couple of dents. One big one on the left side.

After a third round of paint stripper and a bit of scraping and sanding:



And the paint scraping tool I made while I was waiting for the stripper to work:


Tomorrow will be time for some more sanding and maybe a little bondo. We'll see.

[Laminar]

while I was waiting for the stripper to work

It always seems to take forever, doesn't it?

[HedNut]

Spiffy work! And paint booth....I like it.. watching this closely, as I'll be there sometime soon I hope! Keep up the great photos!
Cheers!

[KB02]

Been cold and wet, so not much progress on the painting front.

Got my dash plate mounting figured out, though:


I lined up the idiot lights like a drag race Christmas tree.


Now I have to decide between polish and paint.

[KB02]

Upon reflection, I think the dash needs to be tilted forward just a smidge.


Got some bondo on the tank.




Just a few little dings to fill in. It looks worse than it really is. I went a little heavy with the bondo.

[KB02]

It looks a little better with the bondo sanded down.





All other panels have been sanded and a second coat of primer applied. Just waiting for the first coat of primer to dry on the tank, then that will be sanded and a second coat applied. THEN I must girt my loins and apply the base coat of color.
(I'm scared... I want it to come out well...)

[KB02]

Ready for color. I had planned on painting this weekend, but it is looking like I will have to work all weekend (bleh...).





Been playing around with strip placement ideas. I like checkers, but they tend to be a bit overdone, so I'm just going subtle with black.

I'm thinking this right now:


Although my wife says she doesn't care for the whole stripe thing to begin with - especially being off center. She said I should look to this for inspriation:

Beijing's Birds Nest Stadium.

... darn it... now she has my brain going again...

[Laminar]

I like the offset stripes.

[Zaipai]

+1 on the stripes. Nice work on what was a parts bike!

.: Scott :.

[KB02]

Birds Nest Stadium influence - Does it look too "Spider Man-ish?"

[Zaipai]

Yes, however if done correctly it could be pretty cool..

.: Scott :.

[ultragoat]

Birds Nest Stadium influence - Does it look too "Spider Man-ish?"

I do think it looks too "spider man-ish." Also looks too Van Halen-y as well.


I think you're original idea for the racing stripe was classic and cool. I'd go with that. 

P.S. I've really enjoyed reading about your build. I even stole your idea using wood and gate hinges for the fiberglass seat  . Keep up the good work!

[traveler]

NO stripes....one color paint with clear, color sanded and buffed out.

~Joe