3AJ rebuild ... at last

[welshlamb]

These last few posts have also introduced me to Cerakote. Been in touch with my nearest workshop (3 hours drive away of course) but it sounds like a good thing. I'm thinking it might be good for the frame and engine. Maybe shocks and swing arm as well.

I’m surprised anywhere is within 3 hrs of ACT

[Patrick]

These last few posts have also introduced me to Cerakote. Been in touch with my nearest workshop (3 hours drive away of course) but it sounds like a good thing. I'm thinking it might be good for the frame and engine. Maybe shocks and swing arm as well.

I’m surprised anywhere is within 3 hrs of ACT

It's a small country town and that's the way I like it haha

[welshlamb]

The Arrow exhaust was £200 for the whole system.

Correction..£200for the Cerakote was exhaust, carb tops and float bowls and calipers and carriers... so not as bad!

[welshlamb]

Thought I'd check through mybodywork panels etc so they could for painting whilst I'm enjoying all the other challenges this build is throwing up. Ha HA.

1) back two fixing holes on both sides of the fron mudguard broken and repaired by a crettin in a hurry. Will try to improve and glue/rivert a thin metal backing plate on to reinforce for future. Anyone else done something like this?

2) Main fairing the bottom RHS mounting post has broken off/gone missing. Are all 4 posts needed and if si what fixes have any others tried for this?

3) Tank looks clean and undented (HOORAY!) and only a few chips on rear seat unit.

4) side panels...now it gets ineteresting.....

LHS panel seems fine frontt ab to the grooved grommet, rear prong slides into oval grommet main fixing screw lines up.

RHS panel ... front tab into grooved grommet, tand on top rail juts through small slot in the panel and fixing screw lines up...but no ther fixing . There is a small post at rear of the panel but it doesnt line up withany frame hole/grommet and doesnt have any means of being secured in grommet (ie no 'bell end')

Looking at frame photos from Geoff (Thanks!) is seems to show an oval grommet just forward of the large bracked on top rail (Exhaust hangar?) I dont have that on my frame. Headstock, Vin plate and engine numbers all match and Fowlers confrimed 1990 3AJs EU B (faraway blue) [although my VIN plate is rivetted to front of Downtube , not the side as seems the norm!]

Are either my RHS panel or Frame buggered? How should the RHS panel fix to frame?? Help yet again please (and not for the last time methinks!!)



My Frame

mtb bank near me
Geoff's Frame


Geoffs frame again


Inside RHS cover

shell close to me
Detail inside cover

[welshlamb]

Well the rear original disc I could use after a bit of a clean. The front..well thats another matter.
The first pic shows the old and a new Brembo gold series side by side. Check out the wieght difference in the other photos.
Happy now that I've got two decent discs mounted anyway.

[welshlamb]

Defo seems that there's a bit of metal missing here.


Also the bracing on the rear of the hangar mount looks a bit rough. Is this 'home brewed or are all exhaust hangar mounting points like this?

[welshlamb]

She's on her wheels!!





I found the problem at the rear wasn't a bent rim but an improperly seated tyre. Looked really wierd when you span the wheel. Deflated it at home pushed bead back and brushed lots of lubricant. Had to take to garage and use 70+psi on the rear before it 'popped' back on the rim. Gods knows how you'd do that on the trail/road. Anyway all seems fine just need some clamp bolts for the rear of the swing arm.

Front on OK, .......what lube does the speedo drive require?

I need to put oil hoses, tank and oil cooler back on,also the hose guard that sits on the bottom rear engine/frame bolt and generally check all bolts are torqued up. Will probably then open up the can of worms that's the wiring loom!! Guess its best to get it routed and electrical items mounted before too many other fittings get in the way.

However I should be able to do a couple more items without prejudicing that e.g carb clean and fit, handlebars and fittings, seat off for recovering etc

Lots of fastener and rubber bits (either missing or badly perished!) needed soon so will try to get a first stab at that over next week. and of course resolve the bodywork issues above and get to someone to prep and paint!

Under no illusions that will happen quickly as I've no 'donor bike' andI got this one dis assembled so only finding whats not there as I reassemble! Monmouth isn't exactly near a heap of specialist suppliers .

For now though I will just be happy to open the garage door and see something that has a frame, engine and wheels all together. (..one year on from my first post in this thread!!)

[welshlamb]

Bike came with NOS gaiters fitted.
Look like OEM as they have the correct groove internally at the bottom to fit on forks
Might have been unused but this is what they looked like when I removed!!



The ones currently fitted I got from Kedo.

[charliext1vj]

reference your question and picture on the exhaust mount - it is a very close up pic but that looks like the seat mount but yep bent!

[Mezo]

Same happened to my boots & Geoff`s READ THIS.

M.