Make Alp Great Again XL600V Rebuild Project

Discussion in 'Some Assembly Required' started by Mr. Mota, Mar 1, 2017.

  1. Mr. Mota

    Mr. Mota Adventurer

    Joined:
    Jul 27, 2015
    Oddometer:
    78
    Location:
    Ask Alp
    Thanks man! I bought both, went back and forth on which one to use, settled on the remover. Read more than a few times that the converter can only handle a thin layer of rust. If the rust is thick enough than only the surface will convert but the rust underneath remains. Might use it on the tank though. Wouldn't want to see that turn yellow.

    More spray painting. Had another go with the epoxy primer because it looked like it was sprayed on thin. Really cleaned out the spray gun properly this time and there was so much gunk in there. Sprayed so much better after. Sprayed the top coat too and man that stuff is a lot harsher on the lungs and lingers. Had to improve ventilation. All in all not too bad but still plenty of room for improvement. Didn't properly cover more than a few spots on the swingarm.

    Preparing the alloy parts. The frame came back from the powder coater in the city and it looks awesome. Great to see it in good shape for once instead of the state it was in before. Big step forward in the project. Also got the rims back from the sand blaster. Will try to do some work on them with aluminium brazing rods to fill up the rim rot. Especially on the rear. Need to get my hands on a torch first. Will be able to kick the project into first gear in a week and a half and start putting the bike back together again.



    Attached Files:

    #21
    PTYCHRIS likes this.
  2. PTYCHRIS

    PTYCHRIS Adventurer

    Joined:
    Oct 10, 2011
    Oddometer:
    26
    Location:
    Panama City, Panama
    Hello, I was following your rebuild, which I found to be very intresting. Will there be more videos on the progress ?
    Did you finish your rebuild? Do you have a ride report for the trip here in ADV rider ?
    I just completed a trip through Chile and Argentina. I sent my bike from Panama in a container, I found a very resourceful customs agent in Valparaiso, which I can refer if you are shipping to there from New Zealand.
    #22
  3. Gedrog

    Gedrog Been here awhile

    Joined:
    Oct 20, 2013
    Oddometer:
    960
    Location:
    Lost in the Sahara
    You will see more vids on yo-tube when you start watching the ones above I think its up to day 44
    #23
  4. plumer1kt

    plumer1kt Adventurer

    Joined:
    Feb 11, 2015
    Oddometer:
    359
    Location:
    athens,greece
    he's in day 46 now!
    what about the caliper pistons mr.mota?
    you used the old ones?
    #24
  5. PTYCHRIS

    PTYCHRIS Adventurer

    Joined:
    Oct 10, 2011
    Oddometer:
    26
    Location:
    Panama City, Panama
    Gedrog - Thanks for the info, will look it up.
    #25
  6. Mr. Mota

    Mr. Mota Adventurer

    Joined:
    Jul 27, 2015
    Oddometer:
    78
    Location:
    Ask Alp
    Nice to have you along for the ride man. That is nice, bet you had a great ride! Mind naming a few of your favorite locations and tracks/roads? As for that agent drop me a message here or on facebook, thanks. And yes I'm still on the project, did not update here for a couple of weeks and then the build really kicked off again and there was no time to even make the videos. Back on that too.

    Cheers for helping the man out!

    Ha yes indeed! gave them a very fine sanding in some spots and in with the old. Still a struggle man to be honest and even this time I sliced a bit off the dust seal while trying to get one in but so be it. We'll see how that turns out. Nothing like the rear piston which went in pretty smooth.

    A lot has been happening since the last post. Less text this time and more video and pics. Lots more pics too. Re-assembly has really kicked off now and Alp is starting to look more like a bike again with every passing day.










    Spray painting the aluminium parts with etch primer. It is getting colder by the day here so perfect spray painting days are becoming a rarity.
    xrv-P1440954.JPG

    Radiators will get a fresh coat too. Only one layer of topcoat though and none of the fins to keep the cooling abilities intact. As long as they look better than they did before since they are mostly out of sight anyway. xrv-P1440956.JPG

    This is the moment where things start to get real. Bike support ready, freshly powder coated frame ready to receive all the parts! xrv-P1440970.JPG

    And here is a fine selection of those parts painted black. Handlebar came from the Honda shop that way. Standard dirtbike handlebar. Lower than the oem Transalp one so will need risers. This is a really pleasant sight, looking forward to getting most of it back on the bike. xrv-P1440985.JPG


    #26
  7. Mr. Mota

    Mr. Mota Adventurer

    Joined:
    Jul 27, 2015
    Oddometer:
    78
    Location:
    Ask Alp
    Want a small early easy victory so start out with the headlight. The fork clamps and the steering-head bearings follow soon after. Sent a mate back in the Netherlands a picture and he says the bike looks like Wall-E.
    xrv-P1440989.JPG

    Wire harness goes onto the bike and I am surprised by how unfazed I am with that. Should have asked me a year ago to only have a look at the wire harness and that would have freaked me out. Now it doesn't look all that bad. Maybe that will change if I have to do some actual fault finding. Hope not. Work on the Chinese footpegs for an XR600 from eBay which look and feel sturdy. Need to grind off quite a bit off the original support for them to fit. Maybe I overdid it on the right one so that could use a spot of weld later on to lift them back up again a bit. New handlebar clamps and of course the new handlebar. xrv-P1440993.JPG

    Forks get a good clean with scotchbrite pad and degreaser. Don't know if that effects the clear coat, if there is any left at all. Not looking for a chrome like finish here with sanding and whatnot. Also don't want to go that way because then they will require a lot more maintenance. xrv-P1440994.JPG

    Ok, now we are beginning to have a bike on our hands! Alp is slowly coming back to me. xrv-P1440995.JPG
    #27
  8. Mr. Mota

    Mr. Mota Adventurer

    Joined:
    Jul 27, 2015
    Oddometer:
    78
    Location:
    Ask Alp
    And there is the swingarm! Got some help with putting my first ever bearings in. Made a bearing puller/presser with a long nut, bolts and washers. Really like how they designed the inside so you cannot pull the bearings in too far without excessive force.
    xrv-P1440999.JPG

    Some nice long neoprene panty hoses for the lady! Will they protect enough like the rubber boots? We'll find out. xrv-P1450002.JPG

    Airbox goes in a lot easier than it came out. Finish rebuilding the calipers, reused the original pistons in the front caliper. Still had a tough time getting them in and one cut into the dust seal again. Rear brake foot peddle back on. Hopefully the spring connecting to the rear light won't have to be adjusted because that was a bit of a hassle when I did that in Japan once. Some more electrical components. Filled up the handlebar with the throttle, brakes, switches and the new mirrors. They are pretty flimsy and plasticy but I instantly like the new look compared to the previous round ones. xrv-P1450005.JPG

    One of the holes on the chainguard needs to be drilled out just a bit more in order to bolt onto the swingarm. Pretty happy with this piece. Got it off the wreckers back in Holland when browsing parts. I wonder if this was ever in production somewhere or if someone just made this themselves or had it made. xrv-P1450016.JPG
    #28
  9. PerGrus

    PerGrus Offroad is not off topic

    Joined:
    Jun 16, 2008
    Oddometer:
    41
    Location:
    Bestcoast, Göteborg, SWE
    Congratulations that the Transalp is back, just seen episode 57. Been there, done that, almost bought the T-shirt.
    Last 2 1/2 year swapping engines 12 times. If You ever need Transalp parts don't hesitate to ask - plenty of them.
    (or AT-parts) 416 Mm TA-AT, looking forward to Your next report - go for it!
    Midwinter were You are now - Midsommer here in Gothenburg (soon) Left hand for greetings/Per
    #29
  10. iconman

    iconman Good vibrations

    Joined:
    Feb 20, 2008
    Oddometer:
    1,099
    Location:
    Denmark South West WA
    Been watching your episodes on the tube Pedro and really loving the build. I wish I had done something like your trip when I was younger - very envious. Looking forward to the final episodes. Cheers, Richard.
    #30