1985 DR250S rebuild, and garage fun in Tassie.

Discussion in 'Some Assembly Required' started by sruss67, Jul 6, 2020.

  1. Bowler

    Bowler Been here awhile

    Joined:
    Sep 30, 2012
    Oddometer:
    157
    Location:
    Zwolle, the Netherlands
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  2. sruss67

    sruss67 Been here awhile Supporter

    Joined:
    Aug 2, 2009
    Oddometer:
    412
    Location:
    Devonport, Tasmania, Australia
    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.
    Bowler likes this.
  3. sruss67

    sruss67 Been here awhile Supporter

    Joined:
    Aug 2, 2009
    Oddometer:
    412
    Location:
    Devonport, Tasmania, Australia
    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.
    IMG_20210402_143554.jpg IMG_20210402_170748.jpg IMG_20210403_162555.jpg IMG_20210408_171408.jpg IMG_20210406_124516.jpg

    Attached Files:

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  4. mentolio

    mentolio King of the island of unwanted toys...

    Joined:
    Jul 14, 2016
    Oddometer:
    1,502
    Wow, congrats on the swag! Also, the garage space is looking pretty sweet. How many miles do you have on the Suzuki now?
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  5. sruss67

    sruss67 Been here awhile Supporter

    Joined:
    Aug 2, 2009
    Oddometer:
    412
    Location:
    Devonport, Tasmania, Australia
    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.
    smilin jack likes this.
  6. sruss67

    sruss67 Been here awhile Supporter

    Joined:
    Aug 2, 2009
    Oddometer:
    412
    Location:
    Devonport, Tasmania, Australia
    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 :jack
    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.

    IMG_20210411_160440.jpg IMG_20210411_160436.jpg IMG_20210411_160427.jpg
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  7. Bowler

    Bowler Been here awhile

    Joined:
    Sep 30, 2012
    Oddometer:
    157
    Location:
    Zwolle, the Netherlands
    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 :)
    sruss67 likes this.
  8. sruss67

    sruss67 Been here awhile Supporter

    Joined:
    Aug 2, 2009
    Oddometer:
    412
    Location:
    Devonport, Tasmania, Australia
    Great stuff @Bowler got any pics of your garage and tool collection to share?
  9. sruss67

    sruss67 Been here awhile Supporter

    Joined:
    Aug 2, 2009
    Oddometer:
    412
    Location:
    Devonport, Tasmania, Australia
    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.

    IMG_20210627_152601.jpg

    Camshaft is okay.
    IMG_20210629_165050.jpg IMG_20210629_165112.jpg

    Journals etc are okay
    IMG_20210629_165154.jpg IMG_20210629_165159.jpg
    Cam chain holder a tad excessive, but worked bloody well.
    IMG_20210629_165206.jpg

    Piston needs replacing.
    IMG_20210629_170346.jpg IMG_20210629_170356.jpg

    Time for a rebore.
    IMG_20210629_170538.jpg IMG_20210629_170549.jpg

    Stripped bolt hole at exhaust flange in the head.
    IMG_20210630_155214.jpg

    Stripped, rounded, and cracked hole in the other exhaust flange in the head.
    IMG_20210630_155225.jpg

    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.
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  10. nostep

    nostep Been here awhile

    Joined:
    Dec 1, 2019
    Oddometer:
    360
    Location:
    San Diego
    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.
    IMG_20200914_175615.jpg

    Good luck on the rebuild, I know it will be great.
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  11. sruss67

    sruss67 Been here awhile Supporter

    Joined:
    Aug 2, 2009
    Oddometer:
    412
    Location:
    Devonport, Tasmania, Australia
    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.
    AK650 likes this.
  12. cedric

    cedric Been here awhile

    Joined:
    Nov 7, 2006
    Oddometer:
    358
    Location:
    Calgary
    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.
    15F51B5E4B244216A6619A200CDE8836.jpg
  13. sruss67

    sruss67 Been here awhile Supporter

    Joined:
    Aug 2, 2009
    Oddometer:
    412
    Location:
    Devonport, Tasmania, Australia
    Nice one cedric, looks like a cool old bike that gets plenty of use :-)
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  14. sruss67

    sruss67 Been here awhile Supporter

    Joined:
    Aug 2, 2009
    Oddometer:
    412
    Location:
    Devonport, Tasmania, Australia
  15. sruss67

    sruss67 Been here awhile Supporter

    Joined:
    Aug 2, 2009
    Oddometer:
    412
    Location:
    Devonport, Tasmania, Australia
    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
    86534.jpg 86536.jpg

    Then I decided I should make an engine stand to better hold the Dr engine whilst rebuilding it.

    IMG_20210706_162117.jpg

    Cut some tubing and lined up what was planned, then welded together.

    IMG_20210717_130920.jpg IMG_20210717_131026.jpg IMG_20210717_130948.jpg

    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.

    IMG_20210717_134726.jpg IMG_20210717_165948.jpg IMG_20210717_165956.jpg IMG_20210717_170021.jpg

    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. :jack
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  16. sruss67

    sruss67 Been here awhile Supporter

    Joined:
    Aug 2, 2009
    Oddometer:
    412
    Location:
    Devonport, Tasmania, Australia
    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

    IMG_20210718_114835.jpg IMG_20210718_114811.jpg IMG_20210718_114801.jpg IMG_20210718_114753.jpg IMG_20210718_114731.jpg
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  17. Roadracer_Al

    Roadracer_Al louder, louder, louder!

    Joined:
    Aug 5, 2007
    Oddometer:
    2,735
    Location:
    Oakland, CA
    Excellent use of your new tools & skills: something useful, that won't try to kill you if it fails. :)
  18. mentolio

    mentolio King of the island of unwanted toys...

    Joined:
    Jul 14, 2016
    Oddometer:
    1,502
    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…
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  19. sruss67

    sruss67 Been here awhile Supporter

    Joined:
    Aug 2, 2009
    Oddometer:
    412
    Location:
    Devonport, Tasmania, Australia
    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 :jack

    So stop procrastinating already mentolio :wings Seriously though, thanks guys for the kind words, love learning as I age, good for the mind, and future projects :rayof
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  20. sruss67

    sruss67 Been here awhile Supporter

    Joined:
    Aug 2, 2009
    Oddometer:
    412
    Location:
    Devonport, Tasmania, Australia
    My replacement head arrived from China today, quite impressed with the quality, and shipping only took 4 weeks.

    IMG_20210803_163847.jpg IMG_20210803_163916.jpg IMG_20210803_163933.jpg IMG_20210803_163956.jpg IMG_20210803_164019.jpg IMG_20210803_164036.jpg IMG_20210803_164305.jpg

    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 :clap
    JagLite, badmanners, nostep and 2 others like this.