Exhaust!!

 I fabricated a new battery box that will allow the use of the K&N Pod filters. Installed the wiring harness but I have not buttoned it all up just yet. My plan is to get the bike running, make sure I have reconnected everything correctly, and then do the final install of the harness. I also used steel wool to clean the headers and installed the Dan Moto exhaust. Next up is fabricating two supports for the cans that will hook to the back of the peg mounts. The clip on bars with a 3 inch rise have been ordered and should be in next week. I also finally made it over to Battery Motors to pick up the intake gaskets. Next week I should have the intake system back together.

For good measure I set the tank on the bike to see how it would look. The tank and the frame color are actually slightly different on paper but due to the separation I can't tell a difference. After the bars get here I should have almost everything I need to assemble the bike to a point where I can start it. Until next time.

Tear Down

I originally intended only to repair the dented fuel tank that the bike had when I bought it. One thing led to another an now I've committed to an entire rebuild. Here it is when I bought it.

The old adage of things coming apart faster than they go back together remains true. I disassembled the bike over two nights. I tired to document how everything came apart so hopefully I will have a better chance of getting it back together again. I had to get the dents pulled from the tank and then welded back up before sending it to the paint shop.

I sent the frame, swing arm, and hoop out to get power coated. I took the tank and rear fender to the paint shop. From here the reconditioning of the engine could start.

Rather then take the engine completely apart to paint the gear case covers, I did a very careful masking job, which actually turned out really well. 

After painting, cleaning and new stainless steel bolt kit for the engine. 

New rear sets from ducbike. With these added the bike will be solo rider only. I might convert the passenger seat into a small storage area.
The fame came back from power coating looking pretty sweet.

Got the tank and fender back from the paint shop!

top stripe

I sent the wheels out to get powder coated and ordered a few more parts. For the most part the bike is ready to be reassembled. Big projects yet to do include a new battery box, and mounts for the new exhaust.