Topic: Barn Fresh 550 SS Duplicolor Rebuild

[COB550]

   This is what I've started with here in early spring. It's a 75 550 supersport that has been stored in a chicken coup for over 10 years. The bird piss has rusted everything and destroyed the chrome finish so I will bead blast everything and paint it, brush it, polish it, sand it whatever looks cool and different and costs little to no money. Here are some pics to get started. I also bought two parts bikes, a 72 500 and a 550 junker. I almost considered saving the 500 and still may.

[COB550]

Here are some parts bike pics, the scab 550 has some later model wheels and forks on it does anyone know what they are from, just curious.

[COB550]

I know everyone likes pics so here is some of the teardown, boy that header sure is skanky.

[chopstar500]

Good luck with the resto job man. That's a pretty interesting story with the bird piss and all. 

There's a lot of info here to help along the way.

[Dave-and-his-550]

NOte to self: Do not store chrome parts in the chicken coup.

[COB550]

I glass bead blasted the chrome parts, anyone ever try this? As I was blasting when then media blew past the chrome part it streaked light like static electricity or something it was pretty cool, Im glad the blasting gloves are rubber. For lack of any better ideas after blasting I clearcoated the shocks headlight brackets and aluminum bits. It gives it a raw look. I painted the header with eastwoods brush on header paint and the wheels will be gloss black.

[COB550]

Here is the frame and engine going back together. I left the engine in and sanded the frame as well a I could. The welds were rusty still so I painted them with POR15 then Duplicolored the frame gloss black. I like the Duplicolor cause it dries so fast, but Im sure your paying for a 1/2 can of solvent.

[COB550]

Got the swing arm and center stand blasted and painted. Sanded the tank down and found that someone didnt fill in the tank badge areas enough so I will add some filler and paint later I want to get this thing running.

[COB550]

OK I couldnt wait, I got the new front tire mounted here, assembled the forks and front end and rolled out for some pics. Dont have the carbs on yet, need to finish the petcock and put some lights on it. I havent bought any pod filters yet either. What to do for an exhaust? any ideas? I was thinking of a 2.5" glasspack painted black or maybe a cool chrome tip on the header!

[Roach Carver]

tuning wise you will be better off with the stock filter box. do some searching if you do want to go with pods. there is alot of info here to get you ponted in the right directions as far as needle position and main jet size. btw looks good so far.

[COB550]

here are the carbs disassembled and ready to be cleaned, then ready for reassembly after cleaning and polishing the lids and bowls with 00 steelwool. These are now on the bike and waiting for filters. I dont care for the stock airbox its a pain to take out and the boots are all cracked and dry rotted. I still havent picked a muffler yet so I will dial in the jetting after that.

[chrislib]

OK I couldnt wait, I got the new front tire mounted here, assembled the forks and front end and rolled out for some pics. Dont have the carbs on yet, need to finish the petcock and put some lights on it. I havent bought any pod filters yet either. What to do for an exhaust? any ideas? I was thinking of a 2.5" glasspack painted black or maybe a cool chrome tip on the header!

I say go for the chrome tip. I did the same thing,looks good, is cheap and sounds pretty nice. Oh, bike is lookin real good, nice work for little $$$.