My Gp 125 Rebuild

[cuzo]

https://i709.photobucket.com/albums/ww99/cuzo68/GP%20125%20Rebuild/IMG_0457.jpg

Well this is how I pick it up, she's in a bit of a mess.

[dangerousdave]

[cuzo]

yep, I have vid Ill try and get it posted.
Not sure to do it back to an original or a street fighter / cafe racer theme ?

Leaning towards cafe racer,

[cuzo]

https://i709.photobucket.com/albums/ww99/cuzo68/th_IMG_0458.jpg

[N cee thirty]

look forward to seeing you getting her sorted


least you have the weather to enjoy on it !
____________________
'00 Aprilia RS50 > '92 Honda CG > '99 Yamaha Fazer > '91 Yamaha RXS > '79 Suzuki X5 > 01' Honda Cg > 07' Honda Cg > 82' Kawasaki Z200 > suzuki gsxr 400 gk73a > honda vfr 400 NC30 Mod 2 Passed 09/06/2011

Jewlio Iglesias wrote: I actually did vote BNP once

[cuzo]

Vid was done a little while ago, had nothing but rain sinse,

Dont think we have even had a summer yet,

but dose make good weather for tinkering in the garage

[cuzo]

https://i709.photobucket.com/albums/ww99/cuzo68/114.jpg
What a mess.

https://i709.photobucket.com/albums/ww99/cuzo68/120.jpg
Shit was breaking off everywere

https://i709.photobucket.com/albums/ww99/cuzo68/128.jpg

the tape, is me labelling all the wires and cables so I have half a chance at putting it back in the correct place.

[pepperami]

Will be watching this with interest
____________________
I am the sum total of my own existence, what went before makes me who I am now!

[cuzo]

https://i709.photobucket.com/albums/ww99/cuzo68/IMG_0541.jpg

Thought I would start with somthing small, the light bucket was just siiting there on the bench so it was going to be the ginnue pig, it also was a test to see if I could get this part back to life and that would indicate how much I could do myself before putting my hand into my back pocket.

https://i709.photobucket.com/albums/ww99/cuzo68/IMG_0536.jpg
https://i709.photobucket.com/albums/ww99/cuzo68/IMG_0535.jpg

https://i709.photobucket.com/albums/ww99/cuzo68/IMG_0577.jpg
I cut it back gave it a coat of primer and car boged all the defects and gave it a good sand.

https://i709.photobucket.com/albums/ww99/cuzo68/IMG_0604.jpg
2 coats of gloss black enamal, 3 Coats of clear and 4 Coats of turtle wax

[N cee thirty]

looking good!
____________________
'00 Aprilia RS50 > '92 Honda CG > '99 Yamaha Fazer > '91 Yamaha RXS > '79 Suzuki X5 > 01' Honda Cg > 07' Honda Cg > 82' Kawasaki Z200 > suzuki gsxr 400 gk73a > honda vfr 400 NC30 Mod 2 Passed 09/06/2011

Jewlio Iglesias wrote: I actually did vote BNP once

[cuzo]

Will try the tank and custom make a seat this week end, it looks like its going to be raining all week end, sooo loots of time in the garage i feel.

[DrDonnyBrago]

Budget for some new fork stanchions, they are a tad rusty !


keep up the good work

[cuzo]

I droped the shocks of on friday to tecknics - a two week turn around, they will strip them and send the sleaves to somewere in Queensland to get them hard nickled again, then tecknics will rebuild them for me Cost estimate $ 350.00 gives me two paypackets to save.

[cuzo]

The tank

https://i709.photobucket.com/albums/ww99/cuzo68/IMG_0600.jpg
Got to love those hidden surprises.
https://i709.photobucket.com/albums/ww99/cuzo68/IMG_0601.jpg
Bugger, this will take longer than I thought.

Yippe I worked out how to shrink the pics the big ones were bugging the crap out me.

[cuzo]

https://i709.photobucket.com/albums/ww99/cuzo68/IMG_0828.jpg
I poped the dent with a dent puller , the little dent on the side in the other pic I left, as the bog was still tight, boged the rest up, sanded and etch primed it sanded it and used spry primer filler and sanded it again, (Sorry no pics of this i'm going to blame Toohys Extra Dry (beer) just dam forgot ) 2 coats of Mandarine red, then 2 coates of Ceramic clear in mat finish, I used the engine paint version 500-1000 degres celsious cause of 2 reasons - 1 I was told it cures harder, 2 the underside recieves a lot of heat from the motor, sounds good in theory time will tell.

https://i709.photobucket.com/albums/ww99/cuzo68/IMG_0599.jpg

Couldnt find a scraper flexable enough to work to get the curve right on the tank, paint scrapers dont work, I learnt the hard way the dam bog went off before I could shape it caus i was playing around with it to much with the rigid scrapper. stole a DVD cover out of the rack and cut it up to make my own scraper, the plastic was thick enough but still flexable so I could create the curve.

[cuzo]

https://i709.photobucket.com/albums/ww99/cuzo68/IMG_0531.jpg
Decided to do the frame, I cut it back with wheel wire brush on a small drill (wow did that take some time) and sprayed it with etch primer.

https://i709.photobucket.com/albums/ww99/cuzo68/IMG_0537.jpg
Hit it with 2 coates of Matalic gun metal gray and 2 coats of clear, for some reason it doesnt feel as hard as it should be, the constant rain we have been having could be the problem, I will let it go off for a few days, but as it is, it dos'nt look to bad.

[cuzo]

The Seat took longer than I thought and was tough.

https://i709.photobucket.com/albums/ww99/cuzo68/IMG_0767.jpg
The rear rest was an ebay item but was to short and not wider enough for the GP so I Created a template out of cardboard (had shit loads of it lying around after a recent Ikea outing) all I had to do was attach it to the existing seat, so I taped it all up with material tape.
https://i709.photobucket.com/albums/ww99/cuzo68/IMG_0766.jpg
sprayed it with primer just so I could get a better idea of what it was like.
https://i709.photobucket.com/albums/ww99/cuzo68/IMG_0775.jpg
Bogged it with a thin layer of builders bog to get the shape right and infill the board were the back rest is.
https://i709.photobucket.com/albums/ww99/cuzo68/IMG_0776.jpg
Sanded it, this was easier than I thought and quike to do.
https://i709.photobucket.com/albums/ww99/cuzo68/IMG_0777.jpg
Then Sprayed it with some lefter over touch up paint (I think it was from my wifes old car) So now I have a Bung to make the mould.
From here on end prep is everything I found out the hard way.
Coated the Bung with 8 coats of Mould release, Akunuba wax its the same thing and cheaper.
https://i709.photobucket.com/albums/ww99/cuzo68/IMG_0770.jpg
The Goddies, then I coated it with PVA release agent. Dont skimp on this you will see why.

[Frost]

Jesus this is coming along nicely. Looking at the first few pics i thought it was a lost cause and a money pit, but now I don't think i'll be able to look at a rust bucket the same way again

Get moar pics up

[pepperami]

Coming along nicely

Stay busy!
____________________
I am the sum total of my own existence, what went before makes me who I am now!

[dangerousdave]

Good skills !!

Can see this coming on very well by the standard of work so far.

Keep up the work !
____________________
1988 Kawasaki KMX 200

Previous: Yamaha YZF1000, ZZR600, KMX200, DT50, KX80, CG125, PF50

[cuzo]

Shitten bricks at this stage no turning back now, Thanks for the pat on the back though muchly appreciated. Missis wreckons it should have gone in the dumpster bin.

This is the first bike I have ever done up, sadly to say I dont even have a road licence, so I do have alot of drive to get it done and get my licence.

https://i709.photobucket.com/albums/ww99/cuzo68/IMG_0779.jpg[IMG]https://i709.photobucket.com/albums/ww99/cuzo68/IMG_0780.jpg
Wax, Release agent and then Gel Coat. I had to give it 2 coates, finger marks from a 3 year old helper.

https://i709.photobucket.com/albums/ww99/cuzo68/IMG_0782.jpghttps://i709.photobucket.com/albums/ww99/cuzo68/IMG_0783.jpg
Glassed it up - word of advice use the correct quantity of catylist the first run whent off like a rocket.

https://i709.photobucket.com/albums/ww99/cuzo68/IMG_0785.jpg
It took alot of work to pop the mould of the bung. Near destroyed it getting it out.

https://i709.photobucket.com/albums/ww99/cuzo68/IMG_0789.jpghttps://i709.photobucket.com/albums/ww99/cuzo68/IMG_0790.jpg
Remeber I said about the release agent this is what happens. A bit of filler all should be good.

https://i709.photobucket.com/albums/ww99/cuzo68/IMG_0791.jpg
I have a Mould. Now the process starts all over again 8 coates of wax, this time I used 3 coats of release agent (maybe im just doing somthing wrong or the thikness is still not right) and gel coat.

https://i709.photobucket.com/albums/ww99/cuzo68/IMG_0792.jpghttps://i709.photobucket.com/albums/ww99/cuzo68/IMG_0793.jpg
Glassed it up again, the second pic was me thinking how hard it was to pull the mould off, remembering that it is ontop of the bung, and this, is inside the little kicker for protecting the front of the tank . I also backed of the catylist to give me more time to work with it, just ment I had to let it kick of over night.

https://i709.photobucket.com/albums/ww99/cuzo68/IMG_0795.jpg
Hay presto I have a seat, well it wasnt that easy took me frigin 2 hours to get it out, and yes i was right that front section was a nightmere, I purchased fibre glass filler, basically car bog with fibre in it, dam shit to work with as well, then i used fine filler as a top coat over the bits I stuffed.

https://i709.photobucket.com/albums/ww99/cuzo68/IMG_0794.jpg
Left to Right - Template/Bung, The Mould, and the seat.
The best part I guess of doing it this way is that know I will have a mould, that is, if it gets damged or smasshed I can make another one. - NOT -

[cuzo]

https://i709.photobucket.com/albums/ww99/cuzo68/IMG_0835-1.jpghttps://i709.photobucket.com/albums/ww99/cuzo68/IMG_0834-1.jpg

Finshed seat, kind off is a little hard to sit on at the moment, I might leave it for spell, cant decide how to trim it but I do like the look of just rubber, there is a bit in one of the picks that i was mucking around with just to test the idea.

[Frost]

Bigger pictures!
800px x 600px will show up great.

[cuzo]

https://i709.photobucket.com/albums/ww99/cuzo68/IMG_0659A.jpg
New Rims and spokes, thought it would be cool to have the rear spokes black with chrome nipples, I also sprayed the hubs in gloss black. I lased these myself, wasnt that fun, but not confintenough to true them so off to the shop they go.

[cuzo]

https://i709.photobucket.com/albums/ww99/cuzo68/IMG_0553-2.jpghttps://i709.photobucket.com/albums/ww99/cuzo68/IMG_0554-2.jpghttps://i709.photobucket.com/albums/ww99/cuzo68/IMG_0555-2.jpg
Shockies are taking a while, got call today from the shop and as he explains that the tubes are in really bad nick I replied no Shit Sherlock, any ways he suggested I take the outer's and clean them up, so I decided to linish them myself, there's a few nicks in them that I wont be able to remove, but it does add character. Should have them back before the weekend.