panel damage ...such a pain !!! ...happened whilst moving in plastic storage containers …. not enough packing and too many things in the same box  … the lower panels came off worse ...but blemishes and scratches abound .


oh well... time for a fresh coat of paint and finally  clear coat in a few days

bit of mucking around , waiting for paint to dry

just thought to throw the empty gearbox im intending to use on the back of the motor , to check continuity of finish


looks reasonable I guess  (done some time ago now ) ill populate that box in the coming weeks




and el cheapo thread repair kit arrived , thread fitted , and installed , all tightened up beautifully




think ill make a box out of wood , about the same height at if the engine is sitting on the centre stand = 8.5 inches

and move the assembly out to where I can throw the frame over it, in the garage , once finished enough to run

that way I can install all the driveline ,. and engine running components , all mounted up, in preparation

now to prepare for the KRR down dungog ways this weekend

today replaced all the seals inside the gearbox , ready for driveshafts

and some detailing on the frame stuff  (still cant find that toolbox lid though ...giggles ...its here somewhere !!!  )




got the timber to move the engine outside a bit as well

I like this thread - I keep a snapshot of Charlie's engine in my head, and pretend it's mine when I'm visualizing my latest project.

     thanks Chris ...wish I had a few of your skills .. cheers

RicK G wrote:Some good advice Charlie, don't change the serial number it can lead to disastrous consequences if it is picked up.

Agree. If I am not mistaken, possibly illegal.
Serial numbers help identify bikes.

Chanhanging the serial might also create legal issues.
If you referring to the VIN,  it’s definitely illegal to alter.
Just my opinion.

Cheers

the sump is the only thing being changed ...all the rest, original , even within a thousand in the engine serial number (same week , year and engine designation )

Can't see a problem. It's your engine, you can write on it what you want. VINs are different.

In the UK it would only be an issue if you had done it to fiddle the point-scoring system when applying to the ministry to re-use the identity (i.e. the registration number/plate) from a donor vehicle.

I was taught to use the dictum: 'where's the evil?' This always helped in real-world policing.

refurbished HES sensors (replaced )

and re- installed back to the block




new to me engine mount bolts arrived , so treated them



refurbished coil packs , with some tlc to the laminated cores (rust converter then repaint ) and new rubber isolators on the mounts






looks ok I guess

a few things today , but  also, started with the radiator and the aftermarket fan , this one, care of alby









but I seem to have  misplaced the radiator top section stand off rubbers to the frame ….anybody have a couple of spares ??? before I go looking at the usual places ???


some injector refurbish stuff heading off to Tom in the next couple of days also

Suzuki tb rubber clamps arrived today
seems they will fit up nicely .. and re-useable



hmm ok you guessed it , not happy to leave them boring black ...lets see if this works



the old theory , if your doing something different , why hide it , surely highlight it ???  please forgive my colour choices   im a different kind of weird  and sleeper - lazy builds just don't cut it with me … just too many out there demanding high dollars for crap

I have some orange paint somewhere from "Jaffa", if you want to attract the eye. Somehow I don't think that it will go with the rest of your build.

lol, nice thought Stan  that colour you have is pretty special indeed

ive the thought to put a touch of red in there some where …..extremely minimal all the same , just a touch

thoughts ?

charlie99 wrote:lol, nice thought Stan  that colour you have is pretty special indeed

ive the thought to put a touch of red in there some where …..extremely minimal all the same , just a touch

thoughts ?

All the screw heads? 

 Bill

charlie99 wrote:sleeper - lazy builds just don't cut it with me … just too many out there demanding high dollars for crap

Strewth, mate. Look at this pile on Seattle Craigslist...wow, such a deal, and where is the art of the build?
Craigslist K100-16V

hmm... interesting stuff eh ? no idea what that guy was thinking ,
anyhow
clamps fitted up nicely ,
headlight night light mod almost comlete ,
cutout of fused cable from a headlight fault complete ,
and new cables added to the loom for... future use , including additional relays to the fuse box to relieve the handle bar switches and wiring issues , plus new cabling for controls on dash pad ....not far off

now I can wrap the loom back up and install

a few connectors will need replacing , including the gpi connector as it hits the loom , yes  someone had a go at fixing (likely a neutral light fault ) issues before me .

productive day

Where are the white cable ties?

   hmm you'll have to wait and see stan ...giggles   there maybe some going to hide in weird places I recon .....lol

Gees Charlie ...can you let me know what camera you used to take frame pics..must be a super fast camera to catch a red frame bike as if it is standing still ( they do go faster so i have been told).

Umm...can I just point out...

the Phillip's head screws on the clamps (post 366) are not orientated the same. It looks really messy when they all over the place like that.

thanks guys constructive criticism  always works ....lol

just some more assembly pics , trying to make new main fairing frame brackets from the down tubes to the under side








headlight parkers mod



blast found this , rt style instruments bracket  hits the fairing screen inner ...ill need to search for an rs bracket I guess , or mod the one I have

thought it looked ok for clearance till I mounted the surround

update



still heaps to do ...but progress

under fairing scoop for cooling started 3mm aluminium

gives extra strength and a good base for Drl s to be fitted soon

Make your own instrument panel mounting brackets - I did. Instead of those big fat OEM rubber mounts I used straightforward rubber grommets for anti-vibration mounts. It also meant I could lower the instrument panel to give a better curve for the clutch cable and to avoid hitting the fairing.

https://www.k100-forum.com/t10428-comberjohn-s-ghost

Post 28, pic 3. That was the first attempt. I made a much neater set for LFB.

cheers Dai

may have to do similar

but one of the parts suppliers has the rs type for $19 aussie   and local  sort of  $30 should cover it

side pockets on the rs fairing,,,,,?  why not , handy things indeed , even if its just for the phone ,ciggies , torch etc








the project continues

last one for a few days ...will be away travelling

some exhaust bling

Sorry Charlie but are you going to colour match the masking tape and at least flush fit the ends of it ..or are you now going down the cafe racer look?....

lol... too good mate ...thanks for the giggle

a trip north to help , and to get some supplies

some of what I brought back

stainless stuff  , electric connectors , and a couple of hard disks ...living in the country has some disadvantages  but great when you can visit the BIG SMOKE  to resupply

the cost saving just on the hard disks paid for the fuel for the  trip

a couple of things today

fitted up the grab handles to the ducktail and a few other things

more playing around with metal . paint and parts

fitting a panel for mounting drls , and heat relieving air flow through the fairing vacuum bubble

details - details

braided lines (from Inverell ) and instruments mount (from Bega )





clean up has started already
first, corrosion removal


etch primer



and some colour , clear coat tomorrow ?

My, my aren't those braided lines quite stylish looking!

lol thanks Woodie   all in a theme I guess

resprayed the rear master cylinder ..to match a little better ..




and finally got what appears to be the right instruments bracket for the fairing - spider

cleaned up




seems to fit up ok




waiting for some leds to turn up for the instruments refit

Looks good Charlie

Was amazed at the amount of views - is this a record on the forum?

Am worried that silver spray paint can't be got for love nor money in a 50 km radius of your house.

Guy

lol thanks Guy

the colour is aluminium ...(well what it says on the spray pack )  ...and is just a colour coat ...so lasts a good deal of coverage

forum record ?
no sorry "twb" (Darren)  has that rapped up ...many times ...in a few threads    followed by our old friend ...but sadly missing  "old goat "  (Jason ) ...the bismark restoration from a few years ago 

what I do hope to achieve is ...some inspiration for others to get in there , elbows deep     ,,,as practiced by quite a few so far  ...thankfully for all of us appreciators

I do hope to get this beast on the road soon and hopefully get the time to do the output shaft on old gerty ..again ..forever getting me places I haven't visited before ..along with the group rides and adventures amongst the forum members

so much to do ahead

cheers

charlie99 wrote:lol thanks Guy
forum record ?
no sorry "twb" (Darren)  has that rapped up ...many times ...in a few threads    followed by our old friend ...but sadly missing  "old goat "  (Jason ) ...the bismark restoration from a few years back
so much to do ahead
cheers

Nuh, in individual threads, not even close to Halo's 19,800-plus and Floyd's 14,400-plus, as well as others. The quality of the posts and the replies make a good thread, IMHO. Yours do both in spades, Chazza.

Halo and Floyd ...yep  full of enthusiasm and quality posts
cheers dazza

leds arrived about lunchtime  today  yippee !!!

for instruments refit  and sidelights in rs front indicators





manufactured the circuits soldered in place and circuit board protection lacquer applied by about 3.30 






ordered clear indicator lenses early today which will make a big difference in visibility (orange globes to go in there )

leds function is, they extinguish as turn indicators are illuminated

also added tethers to the wiring to the mirror pods



rj's topbox from rockman (phil out at Inverell , some time ago now , collected and held by seanii ) ..is progressing along with the build...thanks fellas , much appreciated .








additional wiring to auxiliary switches and relays in electrics box also nearing completion with some connectors fitted around the headstock  , a not so easy task for an older fella with shakey hands and tiny crimp connectors,  dash pad will be made out of aluminium ...(of corse ) ...still to do

reworking the instruments cluster

after getting the inverted leds , went further exploring  and found a few more open circuits and shorts in the film circuit , after repairs , now enabling lamps to operate

so installed leds appropriately  with a superior brightness led behind the clock module

this presented another issue with flooding from the extra light from behind the clock module across the tacho and speedo in the centre area and low down

installed some felt around the clock carrier to black out the light wash some

of corse installed an extra led right behind the 70kph area on the speedo side , just to give a bit more clarity at those important mid speeds whilst travelling in regulated speed situations

can actually see the clock at night too , although the contrast of the lcd is a little washed out internally ....likely a polarising voltage issue

more work to go on now with calibration of the speedo to be tested and other functions ..still yet to do

and maybe perhaps a led gear position indicator   although not really important at this time

charlie99 wrote:... can actually see the clock at night too , although the contrast of the lcd is a little washed out internally ....likely a polarising voltage issue

Might also be poor contact on the zebra strips.

robmack wrote:

charlie99 wrote:... can actually see the clock at night too , although the contrast of the lcd is a little washed out internally ....likely a polarising voltage issue

Might also be poor contact on the zebra strips.

will check rob ...thanks for the heads up
 

instruments now mounted  ((screen is being repainted after I scratched it fitting up the rt brackets )  will be back on tonight some time



and started work on a rear mud guard , that should cover a bit more than the immediate tyre sweep inside the frame , and hopefully follow closer to the frame down tubes to the gearbox area

still to build a hump beneath the seat area for clearance

will end up being a two - three part guard , with some trickery around the seat lock and frame lift handle







update

woohoo ,, clear indicator lenses arrived from Germany (just over a week)

looks ok , still to get some lense seals installed , but you get the idea

a little aiming of the indicators inside the lenses required , but should get the look I was hoping for

some pics

picked up some spares from Stan , on the way home from Newcastle , along with an old rt fairing from Tom






these indicator mounts look just fine and part of the parts from someones strip down to make a café ...thing , but will go through the Charlie treatment before making to the red frame project







also Stan contributed a real Rt screen , which has made its way onto Gerty , in preparation for our ride south this weekend , of corse Charlie couldn't leave things alone , and kinda looks ok for 30 something years old now








cant thank you enough Stan , as with all the generous donations , they have found a good home , and will be cleaned up and used  or will be parted out to someone in need

update

I wondered why you hadn't painted the indicator housings white...…..now I know! Looks really smart Charlie.

Paul.

cheers Paul ...

its a little different eh ?