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Rieju RS2 Tidy Up

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Just_James
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PostPosted: 17:24 - 07 Jun 2015    Post subject: Rieju RS2 Tidy Up Reply with quote

So it's time to make a start with this one.

As mentioned in the RS1 thread, I won't be making a proper project of this now as I just don't have the time or money so it will be just getting a general tidy up and fresh MOT so I can move it on.

Shame really as I like the styling of this bike and it has great potential but I can't have everything.

I bought this bike the day after I sold my MR2, I wasn't really thinking but just had cash burning a hole in my pocket and possibly needed to cheer myself up from the loss of the car Laughing

I didn't really take any pics of it when I first got it but I do have the potato images from the gumtree listing when I bought it


https://i9.photobucket.com/albums/a75/RS1Rebuild/_863_zpszt81v8o0.jpg

https://i9.photobucket.com/albums/a75/RS1Rebuild/_86_zpsovuqa9up.jpg

https://i9.photobucket.com/albums/a75/RS1Rebuild/_861_zpstkabjrtt.jpg

You can sort of get the idea from those that the plastics are in a bad way and the bike is just generally a bit bashed and bruised from the young lad keep falling off it.
He was selling it due to the fact he kept falling off and his Dad was now getting him driving lessons instead Shocked Frightening! Laughing


Anyway, it's been sat in the garden under a tarp since last autumn and today I lifted the tarp to give it a quick wash down and have a proper look over it to see just what it needs doing.
I'd already removed the side panels and nose fairing with the intentions of starting repairs on them, they were all held on purely with cable ties! Laughing


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1355_zpsgbvqlwr5.jpg

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1356_zpsc79oqlva.jpg

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1357_zpszzcbhacj.jpg

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1358_zpsbvbddrpy.jpg


My initial thoughts were that it needs quite a bit more work than I remember but as I've gone round it things aren't so bad and it is mostly time and labour I need to put into it.

I tried the ignition 'for what it was worth' not even expecting to get dash lights but to my total amazement the battery had enough juice in it to fire the bike into life! Quite incredible considering it's been sat untouched all this time including over winter! So battery is a good one at least!

Bike runs and idles great and all electrics are working fine so that's all good, bike also has nice low miles.


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1360_zps5b5mdtiv.jpg



Other good points are -

Both Pirelli tyres are good as new and the wheels are in nice condition, just need a clean up.

Chain and sprockets are hardly worn, chain needs a good clean but should be fine.

Everything feels nice and tight with no play so all bearings and bushes etc seem good.

Brakes are great! The discs need a bit of a clean up from being stood outside but there is hardly any wear on them.
They are awesome compared to ones on the RS1 but not surprising considering the size of the discs and the twin pot caliper on the front.

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1367_zpsoukaenzz.jpg


Bad / not so good bits are -

Swinging arm has a lot of corrosion and so it's going to have to come off to be blasted. Bit more involved than I wanted to get but it's beyond a quick tidy up.

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1363_zps59lynbae.jpg


Exhaust needs a tidying cosmetically. It's solid and sound but just has some surface rust and road rash on the can, no big deal.

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1359_zpsphjthjbx.jpg


Hugger is going to need a bit of repair / tidying where the exhaust has been left to rub and melt into it. It's beyond me why previous owner didn't just bend the hanger back - took me all of 5 seconds just using my hands! Evil or Very Mad

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1362_zpspqkysdw5.jpg


Front mudguard needs quite a big repair.

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1361_zpswdpmewkx.jpg


Rear seat lock has the latch bit snapped off but should be easy enough to sort.

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1364_zpsaslpd49j.jpg


Grips need replacing but I already have a new pair that can go on

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1366_zpspcshhzmu.jpg


Choke cable has nothing to connect to, I'm clearly missing a part from the l/h switch gear so I assume thats where it should go. Will try to get a used replacement but otherwise maybe I can just get a spurious lever of some type to connect it to?

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1365_zpsnmtssynv.jpg


Fork seals are well gone so will have to do those.

Other than that it's mostly going to be a case of repairing the fairing panels and respraying it all.
The tail and tank aren't too bad with just minor scuffs and scratches but they've had a previous crappy paint job in black (bike used to be orange) and I need to paint them to match everything else anyway.

Got quite a big repair to do on the l/h side panel Laughing

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP0817_zpsh5inkmxg.jpg


Pretty nasty but already made a start on that Smile

The nose has a split in it and is badly scuffed (this was actually the second one he's smashed, he gave me the old one with the bike too that he'd snapped in half on a previous off!).

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP0826_zpssklx5fzb.jpg


r/h panel is also badly damaged and as with the left side, all bolt holes have been smashed out! Evil or Very Mad

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP0818_zps68t4mpbm.jpg

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP0819_zpsfkh828bz.jpg

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP0820_zpsbcox589f.jpg


.... but other than that it's perfect! Laughing Laughing

Plan to get this done over the next few weeks and am going to try and keep to a budget of around £100.

So... the fun begins! Very Happy
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Current Bikes / Projects: 1999 Rieju RS1 50
Previous bikes - 1986 DT125R (field bike), 1989 KX250, 1980 KX420 (with 500cc big bore), 1992 YZ250, 1988 KX500, 1989 XR250R, 1988 VFR400R NC24, 1999 Cagiva Mito 125, 2008 Rieju RS2 50 , 1993 Honda NSR 125
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stevo as b4
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PostPosted: 20:30 - 07 Jun 2015    Post subject: Reply with quote

Watching with interest! Thumbs Up

Yes it's kind of cool, and trick for a 50cc sports machine with the USD's, fancy discs, Alloy frame etc, but it will never be cool as the original and best (RS1) that you have completed for yourself.

Don't get too interested in this IMO, fix the paint, scuffs, scrapes and Bodges, and get it running with an MOT, and fling it on the bay for 16yr olds to have wet dreams over while asking their dad to lend them some cash. Laughing

Every penny you save on this project, and every £ you get from selling it on can only help in making your Mito resto better and more awesome, is how I would view it all the time your working on it.
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DRZ4Hunned
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PostPosted: 21:19 - 07 Jun 2015    Post subject: Re: Rieju RS2 Tidy Up Reply with quote

Just_James wrote:
keep to a budget of around £100.


100% more interested now. Thumbs Up
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Just_James
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PostPosted: 21:28 - 07 Jun 2015    Post subject: Re: Rieju RS2 Tidy Up Reply with quote

stevo as b4 wrote:
Watching with interest! Thumbs Up

Yes it's kind of cool, and trick for a 50cc sports machine with the USD's, fancy discs, Alloy frame etc, but it will never be cool as the original and best (RS1) that you have completed for yourself.

Don't get too interested in this IMO, fix the paint, scuffs, scrapes and Bodges, and get it running with an MOT, and fling it on the bay for 16yr olds to have wet dreams over while asking their dad to lend them some cash. Laughing

Every penny you save on this project, and every £ you get from selling it on can only help in making your Mito resto better and more awesome, is how I would view it all the time your working on it.


Yeah there are a few bits on this I do prefer over the RS1, I like the fancy dash, the big brakes (they really are good) and the USD forks but in all honesty it doesn't feel quite as well built as the RS1.
Neither are exactly BMW build material but the RS2 does generally feel a bit more flimsy / plastic somehow.

But yes I agree, don't worry, I shall not be getting attached to this one! I couldn't if I wanted to without giving up on the Mito and that's not going to happen!

Just going to do the bit's I've mentioned and move it on - may also load it with LEDs and make it look like something out of Tron! Laughing


DRZ4Hunned wrote:
Just_James wrote:
keep to a budget of around £100.


100% more interested now. Thumbs Up



I think that should be fairly realistic unless I come across any nasty surprises.

Shopping list so far consists of fork seals, choke lever and a pair of indicators for the front. Already have pretty much anything I'll need to do the cosmetic side of things so I'm feeling positive / optimistic Laughing
____________________
Current Bikes / Projects: 1999 Rieju RS1 50
Previous bikes - 1986 DT125R (field bike), 1989 KX250, 1980 KX420 (with 500cc big bore), 1992 YZ250, 1988 KX500, 1989 XR250R, 1988 VFR400R NC24, 1999 Cagiva Mito 125, 2008 Rieju RS2 50 , 1993 Honda NSR 125
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Just_James
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PostPosted: 22:33 - 07 Jun 2015    Post subject: Reply with quote

Have finished the big repair on the l/h side panel tonight.

This is how it started off


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP0817_zpsh5inkmxg.jpg

It was a mess really, not only is that piece broken off but the whole area is severely melted and warped. The bits I need to meet up are so badly warped that they are curving the wrong way! Neutral

Always up for a challenge though and these kind of repairs are the most fun so set to it Very Happy

Started by getting the heat gun on the rear (broken off bit) section first and getting it as close to its original shape as I could then gave it a heavy sanding to remove any high spots.


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP0825_zps2aj7kuyn.jpg

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP0829_zpsjkpccetv.jpg



I gave the main panel the same treatment with the heatgun followed by a heavy sanding. Then met up the two parts and clamped in place


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP0831_zpsfl2dx14a.jpg


I put a couple of plastic weld 'stitches' in just to hold it place while I checked it all lined up back on the bike. Once happy, I plastic welded it front and back


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP0832_zpsxewlbnwt.jpg

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP0833_zpscxloftvv.jpg


Then sanded it back


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP0834_zps4ixjqiez.jpg


The plastic weld gives a really good strong repair (you couldn't pull the two bits apart) but I want to reinforce it from the back to minimise flex so cut out some fibreglass matting.


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP0835_zpsfcztzewy.jpg


Then resin applied, this also helps build up the upper and lower areas where I have lost some of the original plastic


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP0837_zpsaypom6ye.jpg



Then a few skims of flexible filler and sanded to shape


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1368_zpsmrr52ux2.jpg



And finally in primer


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1369_zps4kzo1lbp.jpg



Happy enough with that Thumbs Up

Still got a few other bits to do on that panel alone but it's the biggest repair out of the way.
____________________
Current Bikes / Projects: 1999 Rieju RS1 50
Previous bikes - 1986 DT125R (field bike), 1989 KX250, 1980 KX420 (with 500cc big bore), 1992 YZ250, 1988 KX500, 1989 XR250R, 1988 VFR400R NC24, 1999 Cagiva Mito 125, 2008 Rieju RS2 50 , 1993 Honda NSR 125
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Matt B
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PostPosted: 11:51 - 08 Jun 2015    Post subject: Reply with quote

Nice work Thumbs Up
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dolly3900
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PostPosted: 11:47 - 09 Jun 2015    Post subject: Reply with quote

You Sir, are an artist.

Loved the RS1 resurection and looking forward to this one.

They are great little sports ped, great fun to chuck about (imagine 6'8" of 17 stone loon on one).
____________________
2002 Rieju RS2-50 (Sold, spares or repair), 2010 Suzuki DR-125SM (Traded for ->), 2007 Honda CBF 600 (Sold), 2010 Suzuki V-Strom 1000 (Briefly, now returned), 2007 Suzuki Intruder 1800m (Even More Briefly, traded in for ->), 2014 Suzuki V-Strom 650
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Just_James
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PostPosted: 22:28 - 09 Jun 2015    Post subject: Reply with quote

Ah, an artist is creative... where as I'm just patching stuff up to make it useable again Laughing Thanks for the compliment though Thumbs Up

Been on with the side panels tonight and got them in primer.

First thing I wanted to tackle was the missing bolt holes.

Luckily, the top ones for each side were still attached to the bike so I was able to bond these back in place with some resin


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1370_zpszmua73tf.jpg



They then just needed a bit of a repair on the front side.


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1372_zpsolq6gcpy.jpg



Then had to figure what to do about the others, blu tack was my initial thought.... so I ran with it Laughing

I plunged some clumps of blu tack into each of the holes


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1377_zpsgqrupg9p.jpg



Then smeared some bridging compound over the back.


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP0836_zpsrwoapy8o.jpg


Once that had gone off I removed the blu tack and smeared some compound on the front side too just to make sure it was all solid.


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP0840_zpss3yocith.jpg



Then tidied with a little filler before re drilling.


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1371_zps3jl96pj5.jpg



Sorted Very Happy Thumbs Up


There were multiple holes around the indicator mount areas


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP0842_zpslef35bmy.jpg



Only need the one hole so the rest were just filled with a little bridging compound


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1373_zpsc46xglxb.jpg



The r/h panel was heavily melted and warped at the bottom also


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP0841_zpshptavof9.jpg



So just a tidy up with a couple of skims of filler to make the area smooth again


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1374_zps4md4pghk.jpg



Then finally got them both in primer


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1376_zpsbgc1sybg.jpg

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1375_zps7ckovhga.jpg


That was quite a bit of messing about but beats buying new panels any day! Very Happy Thumbs Up
____________________
Current Bikes / Projects: 1999 Rieju RS1 50
Previous bikes - 1986 DT125R (field bike), 1989 KX250, 1980 KX420 (with 500cc big bore), 1992 YZ250, 1988 KX500, 1989 XR250R, 1988 VFR400R NC24, 1999 Cagiva Mito 125, 2008 Rieju RS2 50 , 1993 Honda NSR 125
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dolly3900
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PostPosted: 09:24 - 10 Jun 2015    Post subject: Reply with quote

Quote:
Ah, an artist is creative... where as I'm just patching stuff up to make it useable again Laughing Thanks for the compliment though


In which case, You Sir are and engineer, a bigger compliment in my book Smile

Keep the pics coming
____________________
2002 Rieju RS2-50 (Sold, spares or repair), 2010 Suzuki DR-125SM (Traded for ->), 2007 Honda CBF 600 (Sold), 2010 Suzuki V-Strom 1000 (Briefly, now returned), 2007 Suzuki Intruder 1800m (Even More Briefly, traded in for ->), 2014 Suzuki V-Strom 650
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Just_James
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PostPosted: 22:56 - 11 Jun 2015    Post subject: Reply with quote

Tackled the front mudguard tonight. Been looking forward to doing this Very Happy .... but then I have issues Confused


Anyway, I've basically got a bit broken off (no surprise with the crap flimsy design) and then that fair chunk missing at the front.


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1384_zpsuqx0gici.jpg



Started by doing a plastic weld on the split at the top


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1386_zpsy9nywcnl.jpg



Then a weld on the broken off bit and reinforced at the back


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1387_zpskslbefw9.jpg



Then sanded back


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1392_zps8uemfgsl.jpg



Then cut a piece of fibreglass matting. This is much thinner stuff than I'd rather have used but it's what I've got


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1385_zpshttvhjyl.jpg



Then in place and brushed with resin front and back


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1388_zpsynvba8nn.jpg



Once that was hardened I put a skim of bridging compound front and back then roughly sanded to shape


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1390_zpsfyt0bugm.jpg

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1389_zpsptaevfbh.jpg


Then a skim of flexible filler and sanded to shape


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1391_zpsh6ujjq6f.jpg



And finally in primer


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1393_zps2l14fe4u.jpg

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1394_zpsoq0axapn.jpg

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1395_zpslziu7ilq.jpg

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1396_zpsiobikccf.jpg


Sorted Very Happy

Thats another one added to the pile Thumbs Up


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1397_zpsozltokzz.jpg
____________________
Current Bikes / Projects: 1999 Rieju RS1 50
Previous bikes - 1986 DT125R (field bike), 1989 KX250, 1980 KX420 (with 500cc big bore), 1992 YZ250, 1988 KX500, 1989 XR250R, 1988 VFR400R NC24, 1999 Cagiva Mito 125, 2008 Rieju RS2 50 , 1993 Honda NSR 125
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Just_James
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PostPosted: 21:51 - 12 Jun 2015    Post subject: Reply with quote

Not really, I've got a broken nosecone of my own to fix Laughing

If you want to have a go at it yourself I'd be more than happy to help you out with it though, you don't learn if you don't have a go Thumbs Up

Only self taught myself and am still learning new stuff all the time from playing at it



I've stripped the back end off tonight to get that swinging arm done


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1403_zpsy2ozjksu.jpg



While the chain was off I d̶u̶m̶p̶e̶d̶ ̶i̶t̶ ̶i̶n̶ ̶a̶ ̶l̶i̶t̶t̶e̶r̶ ̶t̶r̶a̶y̶ placed it in the parts cleaning vessel and left it to soak in some white spirit for a couple of hours


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1398_zps2bqyz0lw.jpg



Then removed and dried


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1399_zpstxlmhbvx.jpg



Then b̶a̶c̶k̶ ̶i̶n̶ ̶t̶h̶e̶ ̶c̶l̶e̶a̶n̶e̶d̶ ̶l̶i̶t̶t̶e̶r̶ ̶t̶r̶a̶y̶ over to the parts lubrication vessel for a soak in oil before hung to drip dry


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1400_zpsegs0bbwj.jpg


Good as new Laughing


Shit, rusty swinging arm is shit and rusty!


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1401_zpsljrm7gjb.jpg

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1402_zps0fsqkwol.jpg


I can't believe how rusty it is for a 7 year old bike Shocked


My weedy blaster will take for ever to do all that so set to it with a flap wheel


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1404_zpswhcm1qm7.jpg



That's as far as I got with it tonight because warm evening and beers in fridge Thumbs Up

Will get it in the blast cabinet tomorrow to get to all the nooks and crannies then see what I'm left with
____________________
Current Bikes / Projects: 1999 Rieju RS1 50
Previous bikes - 1986 DT125R (field bike), 1989 KX250, 1980 KX420 (with 500cc big bore), 1992 YZ250, 1988 KX500, 1989 XR250R, 1988 VFR400R NC24, 1999 Cagiva Mito 125, 2008 Rieju RS2 50 , 1993 Honda NSR 125
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aceofhearts
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PostPosted: 00:02 - 13 Jun 2015    Post subject: Reply with quote

Awesome job! I will have to have a go at panel repairs one day
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Just_James
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PostPosted: 01:22 - 13 Jun 2015    Post subject: Reply with quote

aceofhearts wrote:
Awesome job! I will have to have a go at panel repairs one day


Thanks mate Thumbs Up

Yeah, have a play!

If you've got a panel you'd have binned otherwise you've absolutely nothing to lose other than maybe the cost of a beer or two in materials.

It's no dark art and once you get a basic understanding of how materials work, it's all pretty simple really. Slap stuff on and sand it, if it's not right... slap more on and sand it again Laughing

One of my nephews has taught himself to carve wood, now THAT is an art and incredibly impressive! He is currently carving himself an electric guitar body with an intricate design from a solid block of wood using basic hand tools!

That, I can't get my head around! Shocked You can't make a mistake then add filler or lace in primer to sort it, you get one shot! Unreal level of patience as a minimum and awesome skill! Thumbs Up

Brings repairing a bit of plastic right down into perspective Laughing
____________________
Current Bikes / Projects: 1999 Rieju RS1 50
Previous bikes - 1986 DT125R (field bike), 1989 KX250, 1980 KX420 (with 500cc big bore), 1992 YZ250, 1988 KX500, 1989 XR250R, 1988 VFR400R NC24, 1999 Cagiva Mito 125, 2008 Rieju RS2 50 , 1993 Honda NSR 125
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Just_James
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PostPosted: 20:48 - 13 Jun 2015    Post subject: Reply with quote

Gave the swinging arm a go over with the baster today.
I've only got very fine crushed glass at the moment which wasn't really suitable but it did the job to get into all the tricky bits.



https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1406_zpspeg63kv1.jpg



Theres quite a lot of heavy pitting so I treated it all with rust killer then gave a quick skim of filler over the worst areas


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1409_zpswfzr8mry.jpg



Also wanted to tidy up the side stand and rear hangers as they were corroded so got those sanded down and also treated


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1410_zpss7dj9e0s.jpg



Then got them all in primer


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1411_zpsi4pbitcz.jpg



If I get the time to paint those tomorrow I can rebuild on Monday night and will be making good progress Thumbs Up


Need to order the fork seals (or may try the Fladdem trick first Wink ) so pulled the dust seals off to have a nosey and saw this


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1405_zpsr4ebmezq.jpg



Eh? ... had a little pull of the foreign matter....


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1407_zpsilq9hway.jpg



What the actual fu...


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1408_zpsgflvfl4g.jpg



Appears to be rolled up tissue / grease proof paper! Shocked

I'm assuming previous owners attempt at stopping the leak? New one on me! Laughing
____________________
Current Bikes / Projects: 1999 Rieju RS1 50
Previous bikes - 1986 DT125R (field bike), 1989 KX250, 1980 KX420 (with 500cc big bore), 1992 YZ250, 1988 KX500, 1989 XR250R, 1988 VFR400R NC24, 1999 Cagiva Mito 125, 2008 Rieju RS2 50 , 1993 Honda NSR 125
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ride_to_die
Crazy Courier



Joined: 13 Nov 2005
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PostPosted: 14:19 - 15 Jun 2015    Post subject: Reply with quote

Fork seal bodge is something I wouldn't put past Paddy Very Happy
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Just_James
Could Be A Chat Bot



Joined: 29 Aug 2014
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PostPosted: 21:59 - 15 Jun 2015    Post subject: Reply with quote

ride_to_die wrote:
Fork seal bodge is something I wouldn't put past Paddy Very Happy


Laughing
I wouldn't mind if it was in any way effective but oil was still pissing out and that had just been left stuffed in there!
I was relieved to see there was actually still a seal behind it and that paper hadn't been put there as a replacement Laughing


Bit of progress today.

Postie left a couple of bits for me this morning, a cam lock bar and a universal choke lever Smile


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1412_zpsvamtzu5w.jpg



I want to have a go at sorting the rear seat lock first.

A previous repair attempt of some form has left this glue / epoxy stuff which I need to get out.


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1413_zps4qyuoe2v.jpg



I manage to get an old little self tapper in there


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1414_zpsdqo8q7ab.jpg



Pulled out nice and clean in one go


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1416_zps8s3knlth.jpg



I was expecting / hoping this would reveal a thread but it would appear another previous repair attempt has involved solder. I can see the thread at the bottom but all the top is covered in solder Evil or Very Mad


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1415_zpsqqfnm7kl.jpg


So I drilled and re tapped it to take an M6 bolt


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1417_zps3emu4ibw.jpg



Then bar fitted with washer and bolt


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1418_zpsapefcwdb.jpg



I'd taken a punt / rough guess on what bar length and offset I'd need based on an image I found on t'internet, I figured if I made sure it was on the long side it didn't really matter as I could bend it to fit and cut off any excess if need be.

So went for a trial run to see what adjustments need be made


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1432_zps2jncqgii.jpg



Shocked
It worked 'straight out the box', perfect fit! Laughing

Purely luck, but... BONUS! Very Happy

Sorted Thumbs Up

Cost of bodge £1.40


Onto the choke lever next. I had no luck getting a used replacement so went for this as it looked quite neat.

First thing that was immediately obvious was that I need to remove a lot of outer cable to make it fit.

Next thing was, it is clearly designed to take the smaller nipple


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1419_zpsxrnjeczl.jpg



I don't want to mess around getting a new cable or nipple (in fact I want to try and do it all in situ without removing the cable at all and avoid removing the nipple if I can).

So, out with the drill and bored a bigger hole right through so it will accept the nipple


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1420_zpsbyup3tp1.jpg



Looks like that will do the job.

Next need to figure how much outer cable I need to remove so I thread some wire through and mark where the outer cable needs to end.


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1421_zpsrknbptym.jpg



Then transferred to my cable and marked with tape


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1422_zpsoy8xxvlu.jpg



Then trimmed off the plastic sheath


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1423_zpswkopynxx.jpg



Got the cutting disc on the ferrule so I could split it and remove it


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1424_zpssctlfymf.jpg


Then carefully cut around the outer cable with the cutting disc


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1425_zpsmu9enol4.jpg

Was really proud I managed to cut through that all the way around without going through the inner plastic sheath Laughing


Then stretched the outer so I could thread the inner cable from it


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1426_zpsaefkoh6x.jpg


Then trimmed off the plastic to leave me with just the cable (I'm not bothered about having any kind of ferrule on this for the little and occasional movement the choke lever has - obviously wouldn't do it on a throttle or clutch cable!)


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1427_zpsy9t68vto.jpg


Then assemble it all and hope it works


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1428_zpsh2xrcopx.jpg



It works, and works well! Very Happy Thumbs Up


Struggled for a while trying to find the best place to mount it. Wanted it on the l/h bar really but no matter what configuration I tried it just wasn't going to fit.

Decided best / only spot was going to be on the r/h bar between the brake and throttle.


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1429_zpsdkiuvsv2.jpg


Can't live with that rust there but don't want to get over involved so quick rattle can tidy up on the bar first


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1430_zpsctxjupuf.jpg



Then fitted in place and held tightly with a cable tie / motorcycle assembly strap Laughing


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1431_zps1doturgs.jpg


Works great and doesn't look too out of place, I happy Thumbs Up

Cost of bodge £9.86

So spend counter so far is at £11.26 Very Happy
____________________
Current Bikes / Projects: 1999 Rieju RS1 50
Previous bikes - 1986 DT125R (field bike), 1989 KX250, 1980 KX420 (with 500cc big bore), 1992 YZ250, 1988 KX500, 1989 XR250R, 1988 VFR400R NC24, 1999 Cagiva Mito 125, 2008 Rieju RS2 50 , 1993 Honda NSR 125
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Just_James
Could Be A Chat Bot



Joined: 29 Aug 2014
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PostPosted: 21:05 - 16 Jun 2015    Post subject: Reply with quote

Little update.

Managed to get the swinging arm, hangers and stand painted tonight.


Just a quick rattle can job on the hangers and side stand.


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1433_zps9ukh3d9u.jpg


And the swinging arm in 2k


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1436_zps8uriydjv.jpg



I can start building the back end from tomorrow but first need to at least have a good clean up here


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1437_zpskf5nfo9w.jpg



Absolutely not getting involved in spraying the frame but need to at least make a gesture of something with that rust while I've got access to it.


I am going to tidy up the visible rust on the bottom frame sections at the sides but it will just be a quick rattle can job in satin black.


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1434_zpstckdzp4s.jpg


Also, if you didn't notice from that pic


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1435_zps3ezhxory.jpg


Looks like one of the offs the lad had may have been side stand related Laughing

So, yeah, need to borrow a mig Smile
____________________
Current Bikes / Projects: 1999 Rieju RS1 50
Previous bikes - 1986 DT125R (field bike), 1989 KX250, 1980 KX420 (with 500cc big bore), 1992 YZ250, 1988 KX500, 1989 XR250R, 1988 VFR400R NC24, 1999 Cagiva Mito 125, 2008 Rieju RS2 50 , 1993 Honda NSR 125
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bandit_engineer
Borekit Bruiser



Joined: 01 Oct 2006
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PostPosted: 20:52 - 17 Jun 2015    Post subject: Reply with quote

Really enjoy reading the progress of this project and the RS1.

Keep up the good work Thumbs Up Very Happy
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Previous: 2002 Speedfight 50, 2000 RS125, 2002 RS125, 1997 Bandit 600N, 2003 SV1000S
Current: 2007 GSXR 750 (Isle of Man)
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Just_James
Could Be A Chat Bot



Joined: 29 Aug 2014
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PostPosted: 21:26 - 17 Jun 2015    Post subject: Reply with quote

PaulFzs wrote:
i like your lubricating tray, i have one that looks similar from poundland Wink


Beware of those cheap imitations Tut Tut

Yours may look similar but I can assure you mine is the real deal, it was very expensive! Laughing

I've had some time at home this afternoon so was planning on tidying that bit of the frame and getting on with getting the back end built back up but it's been pissing down all day Evil or Very Mad

Bit limited with what I could do so decided I'd give that exhaust I tidy up, mainly wanted to just sort the rash on the can.


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1359_zpsphjthjbx.jpg


I'm not getting over involved with this, just a tidy up so have a go at just reshaping with a flap disk


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1440_zpsju0myer1.jpg


It's not far off but just need a slither of chemical metal on the expansion chamber side


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1441_zpsey5lr0it.jpg


That will do, it's all going matt black so just give the rest of the can a sand down - not getting involved in fillers or primers.


Gave the expansion chamber a quick going over with the flap disc and wire brush to get any of the loose flaky rust off


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1442_zpskgv3kwc0.jpg


Then gave the whole thing a few coats of matt black - and treated it to some shiny new nuts Laughing


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1444_zpscu6rfk9f.jpg


Came out better than I was expecting for a quick tidy up tbh. Kinda wish I'd gone that bit further and sanded out those other little scuffs on it now... I may revisit it Laughing

Wasn't much else I could get on with so decided I'd clean a few bits up. Rear footrests need a clean up before I put them back on the hangers


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1438_zpsreq9e72i.jpg


I got a bit carried away Embarassed


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1439_zpstiom3k6p.jpg


I just hope they don't make the front ones look odd now because I sure as hell can't be arsed doing those ones too! Laughing


Other than that, indicators have arrived


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1443_zpsuqnvik2k.jpg


£9.95

Spend counter now at £21.21 Very Happy
____________________
Current Bikes / Projects: 1999 Rieju RS1 50
Previous bikes - 1986 DT125R (field bike), 1989 KX250, 1980 KX420 (with 500cc big bore), 1992 YZ250, 1988 KX500, 1989 XR250R, 1988 VFR400R NC24, 1999 Cagiva Mito 125, 2008 Rieju RS2 50 , 1993 Honda NSR 125
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Just_James
Could Be A Chat Bot



Joined: 29 Aug 2014
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PostPosted: 21:09 - 18 Jun 2015    Post subject: Reply with quote

Not had much time to spend on this tonight but I did manage borrow a mig Smile


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1445_zpsjczcdchb.jpg


Obviously assured him I knew what I was doing, no need for any tuition etc. Laughing

I've no experience of welding whatsoever but I've seen it done and figure it can't be difficult Thumbs Up

Anyway, I set to it.... and some events happened Embarassed

Fusion of metal took place, that's all that matters and that's the last that shall be said about it! Hand

Soo we skip conveniently to the 'weld' after a tiny tidy up Very Happy


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1446_zps77mag3zi.jpg



Sorted Laughing


Just need to get rid of all that gunk at the back of the frame now, pretty nasty behind the sprocket cover too


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1447_zpskqwz2zhs.jpg



So, out with the murky white spirit I saved after cleaning the chain my state of the art nano technology degreaser


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1448_zpsyjdmu1vz.jpg



Transferred that to a spray bottle and gave it all a good dowsing and left to soak a while.

I dragged the power washer into the garden and, as I've got the exhaust off the bike, I fit my motorcycle exhaust port plug as a precaution Smile


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1449_zpsjb4s7xgd.jpg



Then gave it all a blast off


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1450_zps2iermq2z.jpg

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP1451_zps1enussbp.jpg



Sorted Thumbs Up


Need to let that all dry off overnight then can just give a quick tidy up of that rust before I rebuild.
____________________
Current Bikes / Projects: 1999 Rieju RS1 50
Previous bikes - 1986 DT125R (field bike), 1989 KX250, 1980 KX420 (with 500cc big bore), 1992 YZ250, 1988 KX500, 1989 XR250R, 1988 VFR400R NC24, 1999 Cagiva Mito 125, 2008 Rieju RS2 50 , 1993 Honda NSR 125
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BravoCharlie
World Chat Champion



Joined: 06 Jun 2012
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PostPosted: 00:03 - 19 Jun 2015    Post subject: Reply with quote

I'm yet to attempt my first ever project bike, but I spend an insane amount of time looking through the show and tell thread on here, and I am in total awe at your work Laughing everyone on here makes it seem so easy!

looking forward to more!
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Past: Suzuki GZ125, Kawasaki GT550, Kawasaki GPX600R, Honda vrx400,Kawasaki Zephyr 750, Suzuki SV650 K5
Dream as if you'll live forever, live as if you'll die today.
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ride_to_die
Crazy Courier



Joined: 13 Nov 2005
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PostPosted: 11:58 - 19 Jun 2015    Post subject: Reply with quote

For someone who hasn't had experience welding you've got some balls to just go for it! I suppose sometimes it's best to just have a crack and see where it takes you. Although I would like to know what happened with the welder? Laughing
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