60/6 Cafe project, Or, be glad you didn't find this on YOUR project

Discussion in 'Airheads' started by bpeckm, Jul 17, 2008.

  1. Stagehand

    Stagehand Imperfectionist

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    #41
  2. JWhitmore44

    JWhitmore44 pistolero

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    That was before the 1st effort. I think it had been leaking for awhile :D
    Before the 2nd effort it took several miles (probably less then 100 but more than 50) to show just a small drip coming off the shelf.
    #42
  3. bpeckm

    bpeckm Grin!

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    To keep my sanity, and a sense of progress, I was continuing to clean bits and pieces of the bike. Did not want to remove the jugs, etc, and was trying to figure out how to clean up the blossoming oxidation of neglect.

    Tried a drill-mounted wire brush, couldn't get down into the spaces very well. Skinny little wire brushes were too aggressive and removed the patina. So, I ended up with what I think worked out well: I fold a green scotchbrite pad lengthwise, and pulled it down into the fins while running back and forth. Lots of cruddy dust later, I sprayed it all with WD40.

    Photo shows front cover (done on the bench wire wheel), the cylinder on the left of the photo has been cleaned with scotchbrite per above, the one on the right is how it started. A dramatic difference!

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    #43
  4. bpeckm

    bpeckm Grin!

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    The big project, totally new to me, was with the front forks. They plunged freely with no damping action whatsoever, so I knew they would need a rebuild :lol3

    With the help of Duane's threads on front ends, and my Haynes, I dug in...:eek1

    Drained the bottom: maybe half a cup of ooze.... Tore it all down, removed the bottom piece and this is the lovely state of the bottom bumpers:

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    #44
  5. bpeckm

    bpeckm Grin!

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    Copious amounts of solvents, long bottle brush, dismantling etc and I was ready to put it all back together. New bumpers, washers, O-rings, wiper rings, check ball springs (that was an effing bitch to get out, til I got some advice on how to pin the sucker from turning while I yarned on the ends...:eek1), etc etc.

    They are back together now, but something ain't right, so I will probably have another version of this chapter later (details to follow:lol3)

    Something relatively clean: oily, not greasy, yeah :clap

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    #45
  6. Stagehand

    Stagehand Imperfectionist

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    What does inside the tubes look like? Smooth?
    #46
  7. bpeckm

    bpeckm Grin!

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    Inside seemed to be in good shape, once cleaned out. The only photo I have shows the original gunky mess inside. I flushed out with gas, ran a towel up and down, and flushed over and over to get them clean. Lots of stuff came out, but the sliders and tubles were smooth when all said and done.

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    #47
  8. bpeckm

    bpeckm Grin!

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    So, working on the well-proven axiom that my time is worthless and cash is scarce, the handwork goes on. Bike was down to the frame, so sanding and priming began. Frankly I was pleasantly surprised at how easily dings an spots filled in, and with Rustoleum's finest grey automotive primer, the frame starts to look rather presentable. The plan is to rattle can with Rustoleum "Professionsal", on the theory that a $6 rattlecan is the finest paint that my money can buy. I found that with lots of prep and sanding 400 grit between coats, hey, I impressed at least myself! :lol3

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    #48
  9. Foot dragger

    Foot dragger singletracker

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    Ah! I did most all this to my R75/6 in the back room of my house over the winter and into the summer,avoided the whole main seal issue so far though.I rattlecanned my frame and you really have to be careful dropping the engine back in or it will scrape lots of paint off. Kinda wished I would have payed someone to put real paint on it as it doesnt look too great once its all said and done, I used the tall can of profesional shiny black.Just looks a little cheesy once all done. Nice work averting the fire and diving in headfirst on the rebuild,having a guru to call on technical bits and reading the book carefully helped me some but I made some real noob mistakes like putting the wrong grease on the splines which all flew off and caused me to take the trans off again.Just the barest coating of BMW red grease is all the splines need,more is not better.(200 hours of labor on mine is probably a low figure,its up and running though)
    #49
  10. bpeckm

    bpeckm Grin!

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    This is one of my favorite shots:

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    #50
  11. Stagehand

    Stagehand Imperfectionist

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    that is a cool shot. :wink:

    Almost fake shiney.

    I dont trust that paint for one minute, though.
    #51
  12. Putts

    Putts Gettin' there.

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    Not the way you or me treat a bike.


    You especially.













    :hide
    #52
  13. bpeckm

    bpeckm Grin!

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    That's why I like the shot....Special Effects Department....thanks to a digital camera with a mind of its own, it shows vastly shinier than actual. All I did was wirebrush the casing with a drill, took the pieces that had come off to the bench wire wheel, and when put back together there is a funky mismatch of aluminum....

    If you mean the black paint on the final drive, here's hoping: I used a green aluminum primer that we use in the marine industry for outdrives, and then Krylon's finest epoxy black paint. "Further developments at 11....."
    #53
  14. bpeckm

    bpeckm Grin!

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    Can't stand it anymore... :eek1

    I have been posting my past work, sorta a lot faster than it has been actually going, cuz I started back in May. I am admittedly farther along than those posts above would have you believe, but I just have to get this off my chest, cuz I got a ride last night.............

    I still have a lot of this project that I have to unload on y'all, pictures of the crap I have found, the problems, etc etc. So never fear, those of you who relish seeing other dude's problems... there will be more..........:freaky

    But, last night, fug it, I put the sorta-OK-paint-job-that-will-have-to-do-for-now tank back on the bike, threw on some fuel lines, and fired er up... really basic balance: sounds good, yep, the other one sounds good. Made up a 3/4" plywood seat and rode her around the block.

    Y e e e e h a a a w !!! :clap


    That lil fix will help me keep going. The morning light was fine this morning, so she rolled out of her dim garage and into the light of day again:

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    #54
  15. Stagehand

    Stagehand Imperfectionist

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    :lol3 :D
    #55
  16. Stagehand

    Stagehand Imperfectionist

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    Nick it from a KTM? :lol3
    #56
  17. bpeckm

    bpeckm Grin!

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    Not yet camera ready, this seat, and a little hard on the bum, but hey, it was better than sitting on the subframe rails...............:lol3

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    #57
  18. bpeckm

    bpeckm Grin!

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    Putts, I am beginning to think that my particular turds are long and shiny... have a bear of a time getting my front forks to do what they spozed to do....The animals have left the garage a few times, now.....:lol3
    #58
  19. Foot dragger

    Foot dragger singletracker

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    The shinyness goes away after a few heat cycles so it will be fine. The forks however can take some doing. Ive read an old article by Joe Minton where he swears by 3.5 wt aircraft hydraulic fluid.I put 10 wt in mine as thats what the book said and they go ridgid over any sharp bump.
    #59
  20. Cat Daddy

    Cat Daddy Been here awhile

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    #60