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Just Dan's little resto on a 34L Tenere'

Posted: Thu Mar 31, 2011 5:56 am
by Just Dan
I was just saying to Andy Gadget that I needed a new project. Now I have finished the R100RS.

Andy said have I got the project for you, in the back of his garage. The last couple of owners gave up on the amount of work that needs to be done to the Tenere going again. It was altogether and just running bit a big knock from the clutch basket. The bike had been passed on from backpacker to backpacker before it sold on again. The speedo shows at least 117,000km (75,000 miles)

Absolutely every thing needs to rebuilt, remade or re welded. This will not be a fast restoration job. Since the bike is pieces, it is hard to tell what is missing. The wiring loom is quite trashed and will need replacing. The first step is to get the frame into shape and paint it then onto making it a rolling chassis. Arrrh where to begin

Any links or info getting parts and encouragement will much appreciated. Now on with the photos for viewing pleasure.

Sad, when a Tenere fits inside a small hatchback
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A few boxes of bits
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The wheels are round, but the spokes are very rusty
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The wiring loom is shagged
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Classic dented 34L tank
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Frame has been broken and bush welded.
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Re: Just Dan's little resto on a 34L Tenere'

Posted: Thu Mar 31, 2011 8:45 am
by Mezo
Just Dan wrote:The wiring loom is shagged
Not as shagged as the one Kylies dog ate. :lol:

:popcorn:

Mezo.

Re: Just Dan's little resto on a 34L Tenere'

Posted: Sat Apr 02, 2011 7:14 am
by Just Dan
Having bit of play in the garage today at trying to find the best way to remove the paint from the frame. Looks like I will doing some welding repairs along the way. Will the frame need extra gusseting? To make it stronger as this bike will be used for outback travel.

The steering head bearings are stuffed. Oh the joy of removing cups. Guess, I will weld them too
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After stripping back the frame. Just got to choose which spray gun to use to paint the frame.
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Too understand how bad the tank is. I started to chisel to the filler away from the dents to see just how rusty the tank is. The tank has had a hard life with a welding repair underneath near the back bone. The good news is. The tank holds petrol without leaking and the rust varies from minor to very rusty, but is repairable.
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Did I mention I hate using paint stripper.

A couple of mates suggested that I should get the frame sand blasted. I thought good idea, but I might just have a go myself with some paint stripper and a buff on the end of a drill. Just to see what happens.

15 mins later. Even emptied a cup of bull dust (Sand ) out of the back bone.
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2 hrs later, sort of half done. After the frame is finished being stripped of paint. I will finish off with some 400 wet and dry to remove the last of the rust.
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I thought, I apply the same process to the tank. With not much luck. The tank has been painted 3 times in it life and I hope it is not the layers of paint holding the fuel in.
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Found out today this Tenere, is a very early one. Number 631 on the production line.


Also picked up the engine today. Complete with gear lever weld to the input shaft. Oh joy with a dremel. The engine has been missing, a oil filter cover and spark plug for a couple of years :eekers:
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On the way home from work. Picked up one of these and some grit. Had a bit of a go without much success. Made a lot of mess without much benefit. Should read the instructions. I think was holding the gun too close to the job.
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Do you think I need a new guard?
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Did I mention that I dislike pant stripper. Finished that messy job. Now onto cleaning up and start on welding up some cracks and remove the old steering head cups from the frame.
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Am I getting any where? The dints and rust is not as bad as I thought. Also will get some POR15 and line the inside of tank while it is naked.
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That's it for a Saturday arvo. Welded up the rear indicator mounts, coil mounts and those pesky steering head bearing cups.

Next stage painting the frame... Welded the steering head bearing cups. To make them easy to remove. :hss:
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Re: Just Dan's little resto on a 34L Tenere'

Posted: Sat Apr 02, 2011 8:46 am
by Just Dan
Time to brake out the spray guns.

Most of the restoration threads, I have read opt for powder coating as their best friend. While powder coating does has some advantages. Like someone else doing the job. Powder coating frames on trail bikes might not be the best thing. Powder coating is tough, but brittle. Once a stone chip starts, it quickly spreads and starts lifting the rest.

I going for the tried and tested method that was done on frames from the 40's on through the 70's. If you own a airhead you might just recognize the color of the primer. I have gone for an epoxy based enamel. Not quick drying and takes a good week to cure. When properly dry, it is tough and flexible.
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Shiny red paint. Just have to let it harden up for a week before putting the new steering head bearings in. Plenty more to get on with while I wait for the paint to dry.
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After I finished painting the frame. I strolled over to Andy Gadget’s for a coffee. Might as well take over the lower triple clamps and press the bearing off. Feels like the bearing has been on for at least a million years. Nothing a bit of heat and a 30 ton press cannot handle.
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A man and his castle or cave.
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Living in Suburbia

Both Andy Gadget and I live in suburbia with our garages under the house. Our poor neighbors having to put up with us. KCRW.com blaring on the radio competing with grinders and welders etc.
Came home from work today and found this on my nature strip. Righto time to break out the sander and finish off the tank while the concrete truck is here. Next step. Try and remove some of the dents out of the tank with stuff lying around the garage.
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Picked up some new head steam bearings for the XT on the way home from work. The head stem bearings are an over the counter bearing yippie. Part numbers 32005x & 32006X. $39 for the pair of Timken bearings

Sand blasted the triple clamps today and put a coat of etch primer to keep the finger prints off
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After reading a few threads on XT's, about engine problems on old bikes . It is starting to make worry a bit about the engine and maybe I should be working on that first. As there is no point having good looking paint if the engine cases are wrecked.

Before I left. I painted a few bits and the tank is starting to take shape. Tried getting the dents out with different shaped levers. Got them about half way out. Very sharp crease was a hold up on the show. The more effort trying to remove the dents. The more the gas cap would buckle.

My work mates reckon I have been a bit slack on this project and I should pull my finger out and get on with it.

The tank is straight and covered in primer filler ready for some clean white 2 pack paint. Before that I need to POR15 of some material like that to line the inside of the tank before painting.
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Tank with primer filler and guide coat.
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New steering head bearings fitted.
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Today, I found a way of sand blasting without making as much mess as normal. I had the bright idea of a big clear plastic bag. Like the one your dry cleaning comes in. I threw the fork leg in the bag. Pulled the rubber glove over my overalls. Put the blaster and your hand in the bag and close the entrance as much as you can. Blast away, still need to wear a mask and goggles. When finished, tip the grit back into your bucket and use again.

While I was doing the blasting. I put some marine clean to soak in the tank to start the process of relining the tank.

Fork legs blasted, etched, silver and clear.
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A bit of work is cleaning up the barrel and side covers for painting.
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Some times it is not healthy for your wallet working the middle of industrial estate. Came home with a small and expensive box of 2 pack be beer primer and colour. Sadly, you cannot buy small amounts of 2 pack paint. I have enough primer for at least 3 - 4 bikes and enough white to at least 2 bikes. Rubbed back the guide coat and squirted 3 coats of primer on the tank. Does not look to bad at all. All I could find is one small pin hole near the top of the tank and rest of the tank looks straight.

Paint, a decent face mask, swing arm bearings and engine seal kit.
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Just the look for the local night club.
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Shiny white paint. Sadly I have to redo it again. Each 2 pac has a different way in the secondary flow rates and I have not used De beer paint before. It is the fastest I seen. It was turning out to be a mirror finish with no orange peel. Instead of tacking off. It did the opposite and the secondary flow kicked in and ran. Looks like a lot more rubbing down to do. I won't get caught out again

Painting is such a fickle game and a very, very fine line between fantastic and fooked. Gloss off the gun with 2 pac is just stunning as you can see the reflection in the photo.
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It is enough to drive a man to drink.

Just figured out why I stuffed up. I have just been reading the product sheet. The hardener, I was sold is a slow drying one. Meaning I need to allow a twice to three times as long between coats. Or spend $35 and get fast drying hardener.

After another joyous hour of rubbing the tank back. Take 2, of painting the Tenere tank. This time I will throw the instructions out the window. Increased the quantity of hardener a little and used no reducer. Still very thin and can run quicker than looking at it. Increased the time between coats to 30 mins. Thats more like it. Mirror finish with very little orange peel and only a couple flecks of dust that can be cut and polished out at a later date. De beers paint has to be the hardest paint I have ever used. It would be very hard for a back yard person to use this paint and get a good job... Glasurit is far easier to use. Pheeeew.
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Re: Just Dan's little resto on a 34L Tenere'

Posted: Sat Apr 02, 2011 9:56 am
by Mezo
Mate you could make a living on that island just with your painting skills, let alone your building skills. :rtfi:

Yourself and Andy.

Dandy bike restorations (Tasmania) PLC :rtfi:

Mezo.

Re: Just Dan's little resto on a 34L Tenere'

Posted: Sat Apr 02, 2011 10:28 am
by Just Dan
I am still up loading the build onto the site as you can tell. Funny you should say working on bikes. I was out there riding for team green on Friday and noticed a small factory that is vacant for a while and has been cleaned up.

Andy Gadget sent me an email from Japan saying there is a full size tire changing machine coming to my place and buy the way could you please stop off at the auction place and buy the wrecked Vstrom that is up for sale, slywink:

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Re: Just Dan's little resto on a 34L Tenere'

Posted: Sun Apr 03, 2011 4:04 am
by Just Dan
While trolling around ebay.de. I found an bought a set OEM handguards
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Re: Just Dan's little resto on a 34L Tenere'

Posted: Sun Apr 03, 2011 4:28 am
by Mezo
This bike is going to be stunning, so have you made space in the living room for it yet? :lol:

I wonder if there's another 34L in Australia like this? ive not heard of one, Just Dan proud owner of Aussie nicest MK1 Tenere. :congrats:

Mezo.

Re: Just Dan's little resto on a 34L Tenere'

Posted: Sun Apr 03, 2011 5:52 am
by Just Dan
mezo wrote:This bike is going to be stunning, so have you made space in the living room for it yet? :lol:

I wonder if there's another 34L in Australia like this? ive not heard of one, Just Dan proud owner of Aussie nicest MK1 Tenere. :congrats:

Mezo.
I am starting to enjoy it NOW. It has got a lot better since the engine is back togeather and in the frame. It is just like a normal bike now. Just chasing individual parts instead of chasing every thing.

The Tenere is pretty good off road. Not sure about the 90º bend in the stair way. :headslap:
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Re: Just Dan's little resto on a 34L Tenere'

Posted: Sun Apr 03, 2011 6:01 am
by Mezo
Easy Dan, handlebars off you steering & the missus pushing and im sure you will make it up there. :lol:

"push girl push and mind the paintjob" :rtfi:

Mezo.