Freshening up...

Hopefully this will stop the gas leak!

Wally World doesn't stock NGK plugs, and their reference books are woefully inadequate. After much eyeballing and deliberation, I settled on a Bosch plug, the 4306.





After installing them, I poked the starter button and got a much more enthusiastic response! I didn't add more fuel and actually start the thing up because I didn't want to fumigate myself.

I moved on to my mirror mounts. These are the Emgo copies of Napoleon bar end mirrors, and the mounting hardware sucks. I devised a scheme with some rubber hose that just fit inside the handlebars, and some anchors that just barely fit inside that hose:





I swear, my engine went together easier than this!
All this just to install some mirrors...

I got a little tiny AGM battery. I'll be installing it where the battery is now, only laid over on it's side. I'm also gonna flip the fender around so it's on the rear again, and I'll cut it even shorter and use it as the battery tray. I'll cut down the plastic inner fender and put it back in it's original place (you won't see it when the seat's on).

So I've been in fiberglass and bondo hell the last few days.





I glassed in the wiring for the tail lights:







First coat of primer.

This is going to be nice, those schoolbus LED surely are big!
Noone cant overlook them!

Hope that China box survive the first days of use, orherwise you have to dig it up from the epoxy again. :laugh:

I think JB weld will do the trick on the tank.



Have a nice weekend!

RoyNor wrote:

This is going to be nice, those schoolbus LED surely are big!
Noone cant overlook them!

I'm counting on it!

Hope that China box survive the first days of use, orherwise you have to dig it up from the epoxy again. :laugh:

Well, I did take the box apart, inspect all the solder joints, heat shrink all the wires, and seal the box up with Shoe Goo (industrial strength rubber cement).

I think JB weld will do the trick on the tank.

It hasn't leaked since I put the stuff on there (crosses fingers).

Have a nice weekend!

Haha, you know where I'll be!

I cut down my inner fender:







I put the back fender back on the back, then started fitting up the little battery:



I'll work more on how to secure that to the frame later.

Meanwhile, work continues on the seat:





The top bolt goes under the rear frame loop, the bottom one is there to help spread the load and I'll attach the ground bus there.

More primer:



I added a coat of this stuff to the underside of the seat:

guitargeek wrote:

Yeah, I started my current project intending to just change some gaskets..

You're worse than my Nephew and I combined!!

I'd say you done passed the gasket change point a "long" time ago :evil:

:laugh:

I cut the rear fender down so it'd fit under the tailpiece:



Alas, the little battery stuck up higher than the big battery had, so I had to lower the fender some. To a achieve this, I needed some spacers...



...which needed to be drilled out...



This lowered the fender about 3/8":







Hey presto, the seat fits!









I started prepping my new battery...





Still working on the battery tray, feathering the battery's nest...



None more black...

I have a decision to make: semi-gloss or satin.



The tank is this cheap Wal-Mart brand (Color Place) satin black, the seat is Rustoleum semi-gloss black.





I'm leaning heavily towards the shiner semi-gloss. It's either go buy another can of the satin and paint the tail to match the tank, or use the half a can of semi-gloss that I still have and paint the tank to match the tail.

Of course, if I don't like how it looks, I can always repaint it...

I need to let it cure in the sunlight for another afternoon before I wet sand and compound and buff.

I worked yesterday on a hold-down strap for my battery:



Too complicated.



Simple and elegant, but doesn't allow clearance for the tailpiece.



Not as simple or elegant as I'd like, but I think it'll do the job.

Enjoying watching this take shape:) I'm looking forward to seeing your paintwork finished,[major,,,expensive,[did I say EXPENSIVE???!!!]pita on my horse].
Those springs look like an exercise in swimming in mud.Your final solution far more practical;)
Keep up the good work.
(and keep the piccys coming!):woohoo:

DZUS!













1.25" Neoprene minicell foam: