Project Scope
I will elaborate on the full scope of the project shortly, so far, I've just made a list of the things that need to be done off the top of my head:
- Paint wheels (rear and new rear)
- Cut unwanted mounts off of frame, weld blanking plate onto frame, apply filler and sand smooth
- Paint frame
- Apply filler to hole in swingarm assembly
- Paint rear swingarm assembly
- Buy/fit new tyre to new rim.
- Clean up/polish engine parts (very long job!)
- Re-assemble engine
- Adjust valves
- Paint valve covers
- Machine up a spacer ring for starter to help engagement and hopefully get rid of the box of rocks noise.
- Drill out pilot jets to 0.5mm
- Drill out main jet to 1.32mm
- Shim needles with 2-4 washers
- Sync carbies
- Fabricate frame mount for pod filter
- Fit K&N pod filter
- Buy/fit clip on handle bars
- Fabricate mount for new speedo
- Buy/fit new speedo (determine drive ratio first, think it's 2:1)
- Fabricate mounts for lowering of headlight
- Relocate fuse box from headlight shroud to underneath seat.
- Modify top triple tree removing extra mounting lugs
- Make 73mm fork spacers, fill forks with oil and re-assemble
- Polish lower fork legs
- Wet & dry upper fork tubes to remove rust
- Fabricate mounts for front blinkers
- Set fuel tank higher off frame at the back end so it's almost horizontal, fab new mounting for it
- Cut existing wiring loom/make another simplified loom to tidy-up/minimalise wiring
- Fabricate new battery housing and mount to rear subframe
- Relocate battery to under the seat.
- Add extra earth cables to frame (these bikes need them)
- Modify rear subframe welding new support legs back to frame
- Fabricate mounting plate for rear LED taillight assy & number plate holder
- Fabricate mounts for rear blinkers
- Fabricate/mold rear set pod from fibreglass
- Fabricate seat and mounts
- Cover seat with foam and fabric
- Cut grind alloy frame support/peg mounts to remove spare hole
- Get superbike footpegs and fabricate mounts to fit to frame
- Rebuild front brake caliper
- Fit new braider brake line and SS bleed nipple
- Fabricate new exhaust pipes (2 into 1)
- Fabricate new gear shift mechanism to suit new peg position
- Fabricate new brake lever mechanism to suit new peg position
- Strip paint off second fuel tank (1st one has too many big dents)
- Apply rust remover and sealer treatment to inside of fuel tank
- Paint tank, rear seat pod and headlight shroud
- Paint switch blocks
- Paint engine oil filler cap
- Smooth and paint fuel filler cap
- Polish rear shock air adjuster
- Fabricate mount for air shock adjuster
- Fabricate new mount for rectifier/regulator
- Replace fuel lines
- Fit new front brake lever
- Refill engine oil
- Refill final drive oil