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Joe that is weird...reminds me of a story I just remembered recently...an old friend had a bike back in the late 80's just like mine that he stripped and re did...real nice...bright yellow, struts and bars, 4 to 1 and pods...really cool. Well he stored it in his dads shed. The 2nd spring, he pulls it out and it was COVERED with rust! His dad had bought new battery for the rider, and improperly stored a little leftover acid on a shelf...turned the environment in the shed into a caustic soup...sold real cheap shortly thereafter. Something on your banket mebbe?

Update: Just completed my first fork re-build! Other than the little caps that went on the end of the factory springs, (which were too large to snap firmly onto new progressive springs, anyway!)I have NO extra parts! I think I actually got them back together correctly! My high tech damper holder...(note the snazzy Fisher-Price handle,LOL!)
A close up of the dampers, showing racetech's suggested "machine work"

The final product, ready to bolt on, and fill! Thanks for looking, and for ALL the help!
Stay tuned!

Latest update: Had some decent weather the last couple of days...conducive to garage activities...A couple "before and after" shots....(hopefully, these will post in the correct order!) Cam cover, airbox, and Engine bling...woohoo!!!!
Re: the airbox refurb...read about it here somewhere, can irrefutably confirm that judicious application of a heat gun does WONDERS for old, sun baked ABS plastic...I don't think the pics do it justice, but WOW! wadda difference!
A BEEG thanx to 74ullc for the re-jetting assistance the other night, Carbs are now ready to sock home into their new mounts! I am now re-jetted, and did it myself! Am ticking off the little projects till I can hear this baby purr through my new Vance & Hines! C'monnnnn Spring!

Looking good and clean!!
Wayne

Be careful there. That engine is getting so clean you may want to sit it on the coffee table in your living room as a work of art. Then you will need to buy another engine or bike so you can ride. It looks really great! Ed

Very nice Grumpy,!
I'm at this stage with my spare motor and I hope it looks that good when it's done.
My hands hurt though

JD

Thanx all! I am tickled at how she's coming along...Ed, believe me, If I could display all this work at home, and still ride her, I SOOO would! (Give the dump some class, LOL!) Blue j....Thanx for the compliment! And I do hear that! This shit IS hard on the old paws, aint it!? (Mine have been throbbing/aching for weeks now! Waiting on my new fork ears, and front end will be going back on...hopefully tonight! Strip/clean/detail back half, and she's well down the road to re-assembly...Given some decent weather, mebbe 2 more weeks til I am riding the old beast again! Still paint work to do, but I will avail myself of mild Spring temps, and do it "Christine style" (a piece or two at a time) in the back yard...If it gets TOO nice, and for some reason, I can't ride her...I get a rash! Thanx for looking, all!

nice.......bike coming along
what are u using to clean between fins?

Thanx spydygon, I've mainly been using nylon bristled "wire brush" type attachments on my drill...I get them at ACE harware...for nooks and crannys, places where the rotary stuff can't go...a rag wrapped around a small screwdiver or paint stir stick....When it comes to scrubbing cases, Simple Green is your friend!

Artist.....Ok
I was thinking of trying out Mothers Cone on a drill and compound.

Stripping foot peg assemblies for cleanup and paint...discovered this...bracket for operators' right peg...hopefully pic is clear enough....looks to me like it broke, and was very poorly repaired...about .25 inch offset...is it supposed to look like this? Can't find anything in my FSM...? Edit: sorry guys should have looked at fleabay first...found a compare...actually supposed to be like that!! WTH? It's half as strong as it could be? Thanx anyway!

Anyone looking at that would think some cockeyed drunk previous owner welded it as you suspected, BUT, they would be wrong. That's how all the 1977 & 1978 KZ650-B & C pegs were made. To me it's one of life's little mysteries. Here's one from my bike. Ed