TOPIC:

I have to make an inner fender that follows that contour. The space will be empty to allow the tire through.

135lbs of compression cold is a good #

leon

That's good news. I've never rebuilt an engine to this extent before, I'm glad I didn't screw it up!

I started forming the inner fender. First I made a form that follows the seats angles, then I got a 10lb block of "air dry" clay from Walmart for $10. I felt like I was back in art class in middle school.

After finding out that I should have replaced the piston pin circlips with new ones I ordered new clips and a head gasket. The new gasket is an all metal type from Kawasaki made from three layers. It measures 1mm thick. The one I removed (which looked exactly like it did when I first took it out of the package) measured 1.5mm. I took the engine apart tonight and will reassemble tomorrow.

Prepping for surgery...

Dissecting the patient...

Half done...

Easy the second time around.

Made some progress

inner fender design

getting cut

gel coat

DONE

Painted the frame. Did a metal blackening thing to the tank and front fender. Mounted a new rear tire and mounted the wheels. I think it's starting to come together now.
before:

after:

Looks like I have the brake drum mounted upside down. oops.