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Discussion in 'Some Assembly Required' started by sruss67, Jul 6, 2020.
It turned out nice @sruss67 !
Thanks @Bowler Pretty happy with it for now, still a little to get it nearer to 100%, but much closer than when I got it.
With the bike mostly finished it was time to remodel my garage work area.
I found the bench space and tool storage have been lacking and I needed to change my layout.
Worked out a plan for maximising a corner in the garage and ordered some ready to assemble cabinets.
Also picked up a new electric hacksaw/bandsaw, TIG welding machine, drill press, and a trolley for the welder and Argon gas.
Will also be building a metal table to weld on which will slide in under my timber workbench, and be height adjustable to suit whatever I am working on and whether I need to sit or stand.
I decided to get the TIG machine having completed a course at Tafe in November 2019, will take some time to learn the settings of the machine and need to relearn the skills used, very excited to get some scrap steel and start sticking stuff together.
Wow, congrats on the swag! Also, the garage space is looking pretty sweet. How many miles do you have on the Suzuki now?
Thanks, mentolio, was my Easter project.
Plan on taking the DR for a ride again soon.
Not too many km after the rebuild, been busy doing stuff at home and in the garden, etc.
Need to replace the rear shock in the DR as the original is about shot.
May need to get the carby ultrasonic cleaned also, few little issues with starting still.
Started hanging tools on the shadow boards and placing tools and other items in the cupboard space.
Forgot just how many tools I have, I guess 25+ years as a bicycle technician lead to me purchasing a few
Got the bikes hanging with the car rack underneath now also, going to put a shelf on top of the bike hanging space to hold helmets and shoes etc.
Assembled my welding cart loosely last night and will finish that tonight.
Then the welder and argon bottle will have a home to stay.
Looking good! I've only recently started collecting tools (when studying I had acces to a fully equiped workshop and just bought a house with garage), but I've already filling my walls as well :)
Great stuff @Bowler got any pics of your garage and tool collection to share?
I have been playing around with carb settings for ages now, trying to get the bike to start well cold and once warmed up.
Was having issues cold starting so asked a fellow bike nut his thoughts and we went over a few things which led me to recheck the compression.
Hmmmm 105psi is not good considering I got 145-150psi before refurbing the old girl.
So, out with the engine and tear her apart to see what is going on inside, and yep, she needs a top-end rebuild.
Camshaft is okay.
Journals etc are okay
Cam chain holder a tad excessive, but worked bloody well.
Piston needs replacing.
Time for a rebore.
Stripped bolt hole at exhaust flange in the head.
Stripped, rounded, and cracked hole in the other exhaust flange in the head.
So I phone around locally to find it will cost me roughly $400 to rebore and hone the cylinder, and to do a valve lap etc on the head, then I need to buy a piston kit and potentially replace the valves and seals etc, so I start searching for options and come up with a new complete head and piston with cylinder kit from a seller on Aliexpress, with reviews saying the parts fit perfectly and work well from a buyer in NZ.
I have bought both sets for a total of $618 AUD including freight to Oz.
Should be about 3 weeks till all arrive and I can rebuild the bike and hopefully all is good then.
Don't know how I missed this until now.
Beautiful work bringing it back from near the grave.
Tidy work space (you've seen pictures of how...not tidy... mine is)!
Also jealous of the TIG! That's a skill on my long term to-do list.
I'm a fan of the cam chain holder, the ceiling can be really useful. I had my suspension off for a week while I was waiting for it to be rebuilt. If I don't secure something, there's a guarantee I'll knock it over. Secured before the legs came off.
Good luck on the rebuild, I know it will be great.
Thanks nostep, the trusses come in very handy when stabilising bikes etc that's for sure.
Your Dr looks safe and sound hanging there
My workshop needed to be redone as it was getting to be a struggle to find things.
I went through a lot of the same stuff with my 81 XT250. I have rebuilt just about everything, and it never seems to end. You have to appreciate the Olds Cool to keep it up. Still puts a smile on my face when I ride it so I keep it around.
Nice one cedric, looks like a cool old bike that gets plenty of use
The complete head I purchased is this one here https://www.aliexpress.com/item/32798160124.html?spm=a2g0s.90423126.96.36.199f2c4c4dKgkYoM
The cylinder and piston kit I went with are this kit https://www.aliexpress.com/item/32896158240.html?spm=a2g0s.90423188.8.131.52f2c4c4dKgkYoM
I mentioned a while ago that I purchased a TIG welding machine and had got it set up to use.
Thought I had best start using it and try to recall what I had learnt in the course I did 2 years ago.
What better way than to buy some scrap steel and start practicing
Joined some angle together
Then I decided I should make an engine stand to better hold the Dr engine whilst rebuilding it.
Cut some tubing and lined up what was planned, then welded together.
Added some brackets to hold the engine at different angle and bolted the stand together. Then added the uprights the rods to hold the engine pass through.
This is the result as of yesterday. Need to get some rod and nuts etc today and move the engine onto the stand.
Pretty pleased with the way it worked out, and with my welding progress. Not the greatest but great learning with different size and wall thickness.
Got out to Bunnings and bought stainless threaded M10and M8 rod, nuts and washers.
Cut it to length and fitted it to the stand.
Moved the engine onto it and it works well.
Just need to wait for the slow boat from China with my engine parts now
Excellent use of your new tools & skills: something useful, that won't try to kill you if it fails. :)
Nice job with the stand! I keep meaning to get off my arse and do something similar for an NT650 v-twin I have on the bench, but I keep putting it off because I want to put it on an engine stand that is currently occupied…
Haha, indeed, and exactly my thoughts.
The next project is my welding table which will involve lots of cutting and lots of welding, excited to do more and learn more.
I have plans to use the welder on a few projects I have thought about for many years, including bicycle frames, some customisation on a motorcycle build, and who knows what else may come up
So stop procrastinating already mentolio Seriously though, thanks guys for the kind words, love learning as I age, good for the mind, and future projects
My replacement head arrived from China today, quite impressed with the quality, and shipping only took 4 weeks.
The cylinder and piston kit never made it and a refund is coming for that.
Have ordered another from a seller on eBay.
Also waiting on a clutch to arrive.
Started looking into purchasing my next project bike, a 1983 Honda XR200R, which was the first motorcycle I purchased for myself back in 1983 ,got my motorcycle license on it, and rode and raced it for a while. Found one in Tassie, rough but mostly there, and running