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Old 06-04-2012, 09:25 PM   #1
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RedKat600's Avatar
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Joined: May 2011
From: LaCenter, WA

I Ride: 2003 Copper SV1K
Restoring my Dad's old Racebike
I thought for fathers day I'd drag this thing out of my shop, clean it up, make it run, make the brakes work, shine it up, and present it to my Dad for Fathers Day. I know it's only two weeks away, but I think I can get it all done since it's in half way decent shape.

The hardest part is the clear windscreen which is custom and currently has a large chunk missing. If anyone knows of a fabber in the Portland local area hit me up. This is not mission critical but if I can get it done I'd like to. Dad says he knows someone that can do it, so it may have to wait. He has expressed interest in doing this in the past, but doesn't currently have the space to do it. I'm thinking if I can get it done, it would probably make his day and maybe inspire him to go buy another bike and do some riding again.

Regardless, this piece of history deserves to be brought back to life. He used to race at PIR in the late 70's early 80's, and was racing at SIR when Mt St Helens blew. He was one of the last people over the Toutle river bridge before they closed it. I'll have to check the plaques, but I know he consistently place in the top three in the class he ran which I believe was 500cc Singles. More details will come.

It's a 1970 something Honda XL 250 with a Powroll bore, stroke and camshaft. I believe it's punched out to somewhere around 380cc. He hand made on a lathe the front and rear hubs to run disc brakes. Hand made the fiberglass fairing, seat, gas tank, and pretty much every other part except the frame and motor. Truly a work of art!!

Progress tonight so far....

Projects

You thought FMF invented the PowerBomb header? Think again. Dad was using that design in the 70's, and here's proof.

Projects

Pay attention to the race number....

Projects

Carb slide
Projects

Inside of the carb bowl.....never seen one quite so black before.

Projects

Projects

So tonight I'm going to source a carb kit. Tomorrow night is to tear down both brake systems and source rebuild kits for those also. After that, it should be cake to make it rideable again.

If anyone has any advice about old fiberglass gas tanks, I'm all ears.

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Last edited by RedKat600; 06-04-2012 at 09:31 PM..
 

Old 06-04-2012, 09:33 PM   #2
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Wyckedan's Avatar
 
Joined: Feb 2010
From: Seattle, Wa

I Ride: An 06 R6 with OPRT
Very cool! Sweet bike!

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Old 06-04-2012, 09:45 PM   #3
Training Wheels
 
Joined: Mar 2012
From: Oregon
Carbs
Can you see the jet size? I'm sure it's not the same as what you would get in a kit. Probably just have to try to polish up the old ones. Just a thought.

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Old 06-04-2012, 09:46 PM   #4
Moto2 Contender
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Joined: Sep 2008
From: where they don't have lawns.

I Ride: on the storm.
Extremely awesome.
It's nice to see you fixing all this stuff up.

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Old 06-04-2012, 09:55 PM   #5
JTR
Novice Racer
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Joined: Feb 2006
From: Ames Lake

I Ride: Yamdalarisosaki's w/ a nos!

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Old 06-04-2012, 09:58 PM   #6
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Joined: May 2011
From: LaCenter, WA

I Ride: 2003 Copper SV1K
“ Quote:
Originally Posted by shanedalion View Post
Can you see the jet size? I'm sure it's not the same as what you would get in a kit. Probably just have to try to polish up the old ones. Just a thought.
Not concerned with the jets. I can clean those up. Concerned with bowl gasket, floats and choke plunger. Choke plunger has rubber on the end and it may not seal well. Bowl gasket is shot. The rest I can clean up as the needle and seat have no rubber, there is no o-ring for the A/F screw, really no soft parts other than the bowl gasket.

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Old 06-04-2012, 10:01 PM   #7
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Joined: May 2011
From: LaCenter, WA

I Ride: 2003 Copper SV1K
“ Quote:
Originally Posted by courier11sec View Post
Extremely awesome.
It's nice to see you fixing all this stuff up.
Did I mention that I'm also pit crew for a Chump car? Sometimes (rarely) I have time to work on my own stuff. Turning wrenches is in my blood if you can't already tell that. If anything is my Zen, that's it.

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Old 06-04-2012, 10:04 PM   #8
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Joined: Jul 2009
From: Beaverton

I Ride: Harley FLHTCU
This looks to be a very cool project.

As to the windshield, I would contact TAP plastics, they carry everything and do custom made stuff.

http://www.tapplastics.com/

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Old 06-04-2012, 10:37 PM   #9
Superbiker
Andy Capp's Avatar
 
Joined: Oct 2010
From: Marysville, WA

I Ride: 08 675, 72 XL250, 93 PW80, 80 GS250
Very cool gift for your pa! Must get back to my project too.

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Old 06-04-2012, 10:46 PM   #10
Moto2 Contender
Avboden's Avatar
 
Joined: Oct 2007
From: from Wa, living on Grenada (island)

I Ride: 1991 XR250L, 2007 BMW F800S, 1999 ATK 605 ESDS/SM
I'd have the inside of the gas tank coated if you're planning on using it, i've used radiator shops to coat metal gas tanks...dunno who would have the right coating for a fiberglass tank.

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Old 06-04-2012, 11:00 PM   #11
Superbiker
Andy Capp's Avatar
 
Joined: Oct 2010
From: Marysville, WA

I Ride: 08 675, 72 XL250, 93 PW80, 80 GS250
“ Quote:
Originally Posted by Avboden View Post
I'd have the inside of the gas tank coated if you're planning on using it, i've used radiator shops to coat metal gas tanks...dunno who would have the right coating for a fiberglass tank.
why would a glass tank need to be lined?

Just re-read the op. I would give alcohol a shot for flushing the tank.

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Old 06-04-2012, 11:15 PM   #12
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Loktite's Avatar
 
Joined: May 2012
From: Seattle, WA
“ Quote:
Originally Posted by Andy Capp View Post
why would a glass tank need to be lined?

Just re-read the op. I would give alcohol a shot for flushing the tank.
Gasoline can delaminate a glass tank, depending on the type of resin used to build it. I heard Caswell is the liner to go to for fiberglass.

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Old 06-04-2012, 11:20 PM   #13
Superbiker
Andy Capp's Avatar
 
Joined: Oct 2010
From: Marysville, WA

I Ride: 08 675, 72 XL250, 93 PW80, 80 GS250
“ Quote:
Originally Posted by Loktite View Post
Gasoline can delaminate a glass tank, depending on the type of resin used to build it. I heard Caswell is the liner to go to for fiberglass.
Thanks. Figured with the join it would have been gelcoated on the inside too.

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Old 06-05-2012, 05:36 AM   #14
Licensed
motodave's Avatar
 
Joined: Nov 2006
From: Bothell wa

I Ride: WR450 08 Ducati mts 1100s
http://www.bikescreen.com/

gustafsson windscreens is the place to get vintage and classic or custom windscreen's

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Old 06-05-2012, 05:54 AM   #15
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Joined: May 2011
From: Everett. WA

I Ride: GS1150 Rat bike, NSR(G)500cc two stroke,CBR 900rr,98 Super chicken
How's the tank look inside? If the carb is any indication it might be nasty. If the paint shows no signs of leaking. I'd clean it with??? Now that I think about it, I'm not sure what to clean it with. I guess whatever will clean out old gooey fuel. Maybe just flush and brush with fresh gas?

When I was 12 yrs old my old man built a 100 gal fuel tank for his F250, never had any problems with it. I think it weighed 150lbs. He made EVERYTHING thing out of F.glass.

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Old 06-05-2012, 06:03 AM   #16
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RedKat600's Avatar
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Joined: May 2011
From: LaCenter, WA

I Ride: 2003 Copper SV1K
“ Quote:
Originally Posted by nsrg500 View Post
How's the tank look inside? If the carb is any indication it might be nasty. If the paint shows no signs of leaking. I'd clean it with??? Now that I think about it, I'm not sure what to clean it with. I guess whatever will clean out old gooey fuel. Maybe just flush and brush with fresh gas?

When I was 12 yrs old my old man built a 100 gal fuel tank for his F250, never had any problems with it. I think it weighed 150lbs. He made EVERYTHING thing out of F.glass.
Yeah, the question is what to clean it with! I don't see any leaks, haven't shined a light in there yet to see. Having a hard time coming up with carb parts. I can find whole carbs, but parts are being difficult. All I really need is a bowl gasket and possibly a choke plunger for a Mikuni VM32. There is no rubber on the float needle and no o-ring for the A/F screw. No real soft parts to speak of.

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Old 06-05-2012, 06:12 AM   #17
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Joined: Oct 2008
From: Kent

I Ride: lawnmower
very cool

whats even cooler is the number 42
Answer to the Ultimate Question of Life, The Universe, and Everything

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Old 06-05-2012, 06:21 AM   #18
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Joined: Sep 2008
From: Kennewick, WA
Blog Entries: 32

I Ride: Whatever old bike isn't broken, 1977 XS-400D (broken), 1978 GS1000E, 1960 BSA C15 (missing pieces), 97 ZX600E ( It's a lover not a fighter)
Ping Wrench about fuel proof resins made for gas tanks.

He's done some work on composite aircraft fuel tanks.

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Old 06-05-2012, 06:46 AM   #19
Retired
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Joined: Mar 2008
From: SE Portland / Bucerias, Nayarit Mx

I Ride: 03' CBR1100XX, 84 GL1200A
Sweet project to have, should be a lot of fun to fire that up.

“ Quote:
Originally Posted by Gotama View Post
very cool

whats even cooler is the number 42
Answer to the Ultimate Question of Life, The Universe, and Everything
You missed... "42o"

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Old 06-05-2012, 06:47 AM   #20
Licensed
Dragonknee's Avatar
 
Joined: Apr 2007
From: Port Angeles, Wa.
What a cool way
To say thanks to Dad..... Great project...

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