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So far the JB has been holding as it has been exposed to gas for several days. Solder would probably have been another good idea.

I finally got everything back together last night and got it going. Things were way off and it took some fiddling to even to get it to run smooth. Turns out that #1 was so far out of sync that it was pulling the rest along and they were barely even firing!

Everything is sorted now and the front brake master cylinder got repaired this afternoon. All that remains is the manual petcock installation and a little cleaning before I take it back to him.

Sounds good, glad to see another one put back on the road and not out to the pasture.

Last night I opened the fuel tank to find a rusty flaky mess. No way was I going to ignore that and potentially foul up the carbs in short order. A coworker had bought a POR-15 tanks sealer kit on my advice, but then didn't even open the box as someone bought the bike they planned to fix! So I bought the kit off of him last night and did the cleaning and metal prep steps. Tonight I'll do the sealer.

Here is the gunk that came out of the cleaning step.

N0NB wrote:

Here is the gunk that came out of the cleaning step.

EEEEEWWWWWWW! :-b

It looks much worse, actually. The flash of the camera allows the bottom of the bucket to be seen. In normal light the gunks is too dark to see the bottom.

I don't know about soldering the cracked overflow tube. I don't think solder would stick to the brass very well, especially since this is (more or less) a high vibration area with the overflow tube having the additional problem of being anchored at only one end. It would act like a kind of tuning fork and might just spit the solder out/off quite easily. A brass brazing operation would be the ticket but would heat up the bowl way too much and may cause it to melt, especially where the tube is press fitted into the bottom of the bowl.
I like the idea of putting a chunk of thin wall tubing over the outside of the tube. An ingenious bodge. I'd use urethane fuel line so it wouldn't harden with fuelexposure/heat/age. The PVC crap that many guys use for fuel line gets hard almost instantly and is totally useless.
I'm still searching for the correct diameter tube but metric brass tubing is not exactly easy to get in North America. Are there any Euro members on here with access to brass tubing ?? Model railroad hobby shops usually carry an assortment of that kind of thing. Maybe in Europe they stock the proper metric tubing ??? Fingers crossed....
Any/all help gratefully solicited on this niggling little matter....

N0NB wrote:

...bought a POR-15 tanks sealer kit...did the cleaning and metal prep steps. Tonight I'll do the sealer....

Was hoping for a live action report on the "b-b's and bolts -- rotate in clothes dryer" method.

This one could probably have used the BBs and bolts in the drier to good effect. However, I did the sealant step last night and it looks to have turned out very well (I did a quick look this morning). Now it needs 72-96 hours to cure.

I talked to the owner yesterday and he said he had put sand and water in it a few years back and let it ride on his pickup for some period of time. It also rusted rather quickly again. I doubt that'll be an issue for him again.

Well, there are no leaks and no rust in the gas.

My neighbor and I rode it around. There is a stumble between idle and about 2500 RPM that I minimized by careful dwell setting and timing. I assume it needs some new ignition parts, but I'm stopping here for now so the owner can ride it and determine how much more he wants to put into it.

So, here are some final pics. Finally out of the garage!

Again:

Other side:

Again: