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Discussion Starter #22
I got the rear brake adjusted, chain slack adjusted, clutch adjusted, brake fluid filled, front signals mounted and headlight bracket made.

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Discussion Starter #24
Been a slow week..... I got the wiring for the signals lights, headlight, and taillight all properly soldered and heat shrunk. I also had to re-wire the clutch lever wires because my new lever tangs didn't match the old connector. I cleaned up and painted the headlight mount I made..... That's about it. Not a real productive week, but work was busy. I'll be back at er on Sunday!
 

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Its looking great....I'm hoping to start mine soon...what are you going to do for a seat support...Fabrication???

Did you just spray bomb the parts, or powder coat??
 

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Discussion Starter #26
The parts I'll be fabbing are the headlight mount, license plate side mount, battery/wiring cover/seat support, rear fender mount, and exhaust. The only other metal work I've done is grinding off the passenger peg mounts on the frame.

Everything is spray-bombed using Rustoleum Auto paint and Duplicolor for anything high-heat. Super budget build... although I probably could've used automotive paint for the same price by the time you start adding up all the spray bombs! I've done both before.... A true 2k paint job is definitely better, but I just wasn't set up for it properly this time around. I fully expect I'll be doing touch-ups since the paint isn't nearly as hard as a 2k job. I did a full 100% restoration of a Massey Ferguson tractor and did a proper hard finish 2k job that shined like a show car. The bad side of that is if it does get scratched/dented it's a lot more work to blend in a touch-up. That just wasn't the intention for this bike. Maybe it'll all flake off after the first month of riding... but we'll see! Haha!
 

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When you say 2k, are you referring to the clear coat? I used 2 cans of that stuff on my bobber paint job... I hope it holds up well, but after 2 weeks of sitting, I accidentally dinged a screwdriver off each fender while installing them, and it chipped down to the primer. Ugh.

-John
 

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Discussion Starter #28
When you say 2k, are you referring to the clear coat? I used 2 cans of that stuff on my bobber paint job... I hope it holds up well, but after 2 weeks of sitting, I accidentally dinged a screwdriver off each fender while installing them, and it chipped down to the primer. Ugh.

-John
By 2K I mean a two component paint. It’s the paint + hardener. It’s what I’d use when mixing my own paint for my spray gun. There’s some options in rattle cans where you have another container inside the can that you “break” and the can is a one shot use.

You did a base + clear.... both paints being “1k” out of rattle cans (I assume).

No question that rattle can look great... it’s just going to be a much softer finish and more susceptible to damage and likely UV rays, etc.

I have several scratches I’ll need to touch up too. You hit any of this stuff with a metal object and it’s gonna scratch easy!
 

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I used spray cans of automotive paint for the color, but used a 2k epoxy clear coat - with the little container of hardener. It's supposed to provide a similar hardness to factory paint.

-John
 

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Discussion Starter #30
I used spray cans of automotive paint for the color, but used a 2k epoxy clear coat - with the little container of hardener. It's supposed to provide a similar hardness to factory paint.

-John
Oh nice! That should definitely help with durability!
 

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Discussion Starter #33
Progress Update

Well it was a crappy Sunday. It started with simply filling the bike with oil so I can get around to starting it. And.... I have a leak. Of course it's in the side cover where the sight glass is, which is impossible to get to without undoing motor mounts and removing the larger stator cover. So I had to remake that gasket. Then I tore the gasket on the stator cover.... so had to remake that one.

That outta the way, I started chasing wires to try and find out why it won't engage the starter. Got kinda lost so I resorted to making a wire diagram specifically for ignition off the main schematics. I also found a short on my right handlebar control and fixed that.

So kind of a 1 step forward 2 steps back kinda day. Nothing really accomplished other than fixing some of my own blunders.

All this for simply starting the bike..... haha. At least now I can start tracing the circuits to see why power isn't getting to my start switch.

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Discussion Starter #34
Sorted half the problem with the starter. A bad wiring on one of the connectors I had apart and the run switch was not put back together quite right. Got power to my relay now! But still not wore to the starter yet... Challenges for another day.

In the meantime, I got the headlight on.

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Discussion Starter #35 (Edited)
Been a while.... this wiring kinda was kickin me (starter). I figured it out though. I had a bad ground at the starter because of all the paint. That problem fixed! She turns over!

I made a seat pan that turned out horrible. It's hideous and huge. I seriously wasn't even going to post the pic it's that bad. But I figure my embarrassment might help someone else that might think.... "Oh, I'll just make a cover for the whole damn thing!"

So needless to say, that got tossed in the scrap bin. It might not look 1/2 bad from the side (2nd pic).... but it's terrible from any other angle and actually cuts into my legs.

So.... next post I'll explain my next approach.

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Discussion Starter #36
I did a bunch of Googling for examples of what some of the pros did when bobbing these bikes and found most chop off the back of that plastic battery housing. So I figured.... sure...

So I hacked off the main harness and extended it so I can move both the fuse panel and IC Igniter over to the right-side compartment. There's lots of room there and they tuck neatly out of sight but are still easily accessible.

Now this leaves me the ability to hack off the back of that ugly plastic and leave that "open" since it doesn't look bad (just shows the top of the shock mechanism). And the battery hold-down and front of that looks ok. So I just need to cover the back side of the battery where the starter relay and all the wiring gathers. One MUCH SMALLER 'cover' to make. And of course I'll need seat spring mounts.

Next step.... solder and tidy up all that wiring!

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(Yes, I see one of the connectors is loose. This was just a test fit). :)
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I’m starting my loom from scratch. And removing every conceivable unnecessary item.
have you kept all the safety switches and warning lights? Just wondered if you’ve just moved the loom about or did a rewire?
 

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Discussion Starter #40
I originally was thinking about starting the harness from scratch, but there are a TON of wires!!! And really, if it ain’t broke...

But what I did have to do is extend the fuse panel connections. That was probably 15-20 wires. I put the bulk of the extra harness in the left side panel. The igniter fit without extending the wires into the right panel.

There’s really only a couple things to remove. The side stand switch (mine was broke, so I didn’t bother with it. Maybe the clutch lockout... not much that would declutter the bike really, and most of the wires are actually pretty well hidden.
 
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