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Rieju RS1 Project

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Just_James
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PostPosted: 20:58 - 29 Aug 2014    Post subject: Rieju RS1 Project Reply with quote

Well this is my first post on the forum so hello to all Very Happy

Not had a bike for a few years but last year decided I was going to part with my car that I've owned for 15 years (and not used for the last 5) to free up my garage space to make way for a bike project or two.

So with the idea in my head I started browsing at bikes for 'research' and to see what kind of things were about.... and within a few days I had a Rieju RS1 in the back of my van Shocked
I then realised I'd forgotten to sell the car first and so had nowhere to put it so the bike sat in the garden (I was really popular with the missus).

That was last summer and seeing as I've still not got around to selling my car I decided a couple of weeks ago that I was going to start rebuilding the bike where it sat in the garden. If and when I sell the car, having a garage to work in will be a huge luxury!

So... here is the bike as it was when I brought it home (sorry for cr@ppy phone pics).

https://i9.photobucket.com/albums/a75/RS1Rebuild/IMG00076-20130728-1804_zpsfebaca4a.jpg

Doesn't look too bad at a glance but that was after a heavy jet washing! The previous owner who ran it into the ground had fashioned a piece of tin plate with his teeth then self tappered it into the tail fairing to replace the missing seat- I had removed that for the picture!

I'm well aware the bike is going to need a lot of work and parts (which can be hard to come by) but I got the bike for £80 as a runner (astonishingly it actually had a short MOT too) so I've got a fair budget to throw at it.

https://i9.photobucket.com/albums/a75/RS1Rebuild/IMG00075-20130728-1804_zps3e07f976.jpg

It is missing its side fairing panels, the screen is broken and the plastics that are present are in a really bad state with cracks, bits broken off etc. There are also several hundred layers of bodge paint to contend with too!

https://i9.photobucket.com/albums/a75/RS1Rebuild/IMG00080-20130807-1324_zpsc6c77133.jpg

The frame and swinging arm etc are in a really rough way so the bike will be having a full strip down and I don't think there is much that won't be getting touched! The bike was previously owned by a young lad who obviously did nothing to look after the bike other than keeping it going to for his commute to work.

The good points are, it runs and actually runs very well. It has had a new battery, new radiator and some hoses...... erm... I think that's it.

So for the past year while it has sat in the garden under a tarp, I have managed to pick up a few spare parts for it so have....

Brand new screen.
Fairing side panels (used and damaged)
Rear seat (used with no lock or cover)
Speedo drive (used)
Extra set of wheels with new tyres
Extra set of forks with new seals
Brand new lock set with ignition barrel etc
Brand new chain and sprockets
... and some more bits on the way..

Now I hadn't really planned on doing a thread about the bike and so don't have many pics of what I've done so far but will keep up to date as of tomorrow! Very Happy

Here are a few of the bike as it was being stripped, plenty of corrosion etc to deal with - I don't understand how as the entire bike was encrusted with oil and hadn't seen a wash in years!

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP_0636_zpsf10f86c9.jpg
Some damaged melted wiring due to some seriously rough welding of the headlight bracket!

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP_0638_zps19da03a3.jpg

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP_0641_zpsffc2bc03.jpg

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP_0642_zpsed8a71e5.jpg

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP_0645_zps9ba8e203.jpg

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP_0662_zps4b0618d9.jpg


So, the stage I am up to now.... bike was stripped down to the frame last week. The frame and sub frame obviously had some heavy corrsion and really needed blasting and powder coating but I wanted to avoid this cost so was in two minds whether to prep it all and spray it myself or perhaps just have it blasted and then prime and paint it.
Anyway, long story short... I got talking to a lad who can do powder coating as a 'foreigner' and said he could do it (frame and sub frame) for £50... including having it blasted Shocked
... so I left it with him!

Picked them up a couple of days ago and.... I'm trying not to be disappointed Sad

He's done a lot of work for £50 and I just can't grumble or complain at that.... but I'm just not happy with it. He's been too shy with the powder in places and it generally has a pretty rough finish - not what I'd expect for a proper powder coat job... but yeah, I should've paid £120 then!

So I was then left with the decision of whether to start rubbing it all down to wet spray myself or to live with it, after all, it does have a layer of powder on it and all that corrosion has been blasted off.
I couldn't live with and couldn't bare the thought of rubbing it all down so went for a compromise and just resprayed the bits that were going to be visible once it's rebuilt... not what I wanted but it's what it is

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP_0669_zps0f0c8090.jpg

While the engine was out, I've given it a lick of paint, done an oil change, given the carb a good clean etc. Not much to do here though as it does run well, looks to have had a relatively recent piston and barrel.

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP_0664_zps07fc7324.jpg

Also done the swinging arm - sanded, primed and painted

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP_0666_zps7f128e20.jpg

So with a frame I'm finally 'happy' with and a few other bits and pieces done (will add pics later), the build starts tomorrow Smile

I will update as I go along Smile
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Nisp
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PostPosted: 22:14 - 29 Aug 2014    Post subject: Reply with quote

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP_0664_zps07fc7324.jpg

that is one incredably small carb.....
treat your self to a proper one in the future Smile

it would be interesting to see how this bike turns out, a lot of us (me included) have a fetish for anything two stroke.
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Carvel
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PostPosted: 22:21 - 29 Aug 2014    Post subject: Reply with quote

All I can say is I hope it was free.
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PostPosted: 22:45 - 29 Aug 2014    Post subject: Reply with quote

https://www.ebay.co.uk/itm/161393762335

You know you want to.
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Just_James
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PostPosted: 22:48 - 29 Aug 2014    Post subject: Reply with quote

Nisp wrote:
https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP_0664_zps07fc7324.jpg

that is one incredably small carb.....
treat your self to a proper one in the future Smile

it would be interesting to see how this bike turns out, a lot of us (me included) have a fetish for anything two stroke.


Yes it's a pretty tiny carb..... 50ccs don't need much Very Happy

My last bike wasn't big by any standard (VFR400RR) but it makes everything seem pretty miniature on this thing but I thought it would be a fun project and grew up with 2 stroke crossers and still love that smell of 2 stroke in the morning Very Happy


Carvel wrote:
All I can say is I hope it was free.


£80.... running and with some tax and MOT Very Happy

Breaking it for spares would have been a profitable route especially with how rare parts are but but I've never had a little bike and when I saw this I just couldn't resist it as a little fun project Very Happy
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binge
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PostPosted: 22:52 - 29 Aug 2014    Post subject: Reply with quote

Awesome!

I love a little bike project. I'd if been far too tempted to stick a 125 in it while it was apart though. The R2k engine looks like it'd go in pretty easily from the TZR125.
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Just_James
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PostPosted: 22:58 - 29 Aug 2014    Post subject: Reply with quote

Nexus Icon wrote:
https://www.ebay.co.uk/itm/161393762335

You know you want to.


I've certainly looked at them.... Very Happy

I just doubt their reliability at that money and then theres upgrading carb' etc to go with it?

Proper branded big bore kits are into the hundreds and I just don't want to spend that kind of money trying to squeeze a horse or two out of this thing.
Would be fun to get some more power from it but I don't know if this will be a 'keeper' as a bit of fun or whether I'll just run it a while and then sell to get a fresh project..... all depends when it gets finished and where I stand with the garage.
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Just_James
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PostPosted: 23:23 - 29 Aug 2014    Post subject: Reply with quote

binge wrote:
Awesome!

I love a little bike project. I'd if been far too tempted to stick a 125 in it while it was apart though. The R2k engine looks like it'd go in pretty easily from the TZR125.


Yep it would be fun to do something like that and similar thoughts had crossed my mind but my budget and time limit aren't huge while I'm building this in the garden and heading into autumn so priority really is to get it close to standard. Also, I think searching for parts for this thing over the past 12 months has given me a little respect for just how rare these bikes are (try and find some for sale) and so altered my 'plans' for it a little so I think keeping close to standard is probably the best way to go anyway.
I'm not suggesting they are a collectors classic or anything but think it needs some integrity - if it had been an RS50 or similar I would probably do some more radical changes
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stevo as b4
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PostPosted: 07:46 - 30 Aug 2014    Post subject: Reply with quote

Good luck with this project, you might need it judging by the state of the wiring!

Anything you do to it will make it look a million times better than it was that's for sure!

Anyway, what is this long time owned car stuck in your garage, that you just can't bring yourself to let go?

The reason I ask is that it's a familiar story to me, I have a car that I cannot really ever sell without a massive loss, and has been sat for over a year now unused in my garage.

Worst bit was that 2years ago I spent over £500 on painting, electrics and fitting out my garage to make a nice clean workshop for bike stuff, and now I can't even get in there! Sad
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Just_James
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PostPosted: 11:19 - 30 Aug 2014    Post subject: Reply with quote

stevo as b4 wrote:
Good luck with this project, you might need it judging by the state of the wiring!

Anything you do to it will make it look a million times better than it was that's for sure!

Anyway, what is this long time owned car stuck in your garage, that you just can't bring yourself to let go?

The reason I ask is that it's a familiar story to me, I have a car that I cannot really ever sell without a massive loss, and has been sat for over a year now unused in my garage.

Worst bit was that 2years ago I spent over £500 on painting, electrics and fitting out my garage to make a nice clean workshop for bike stuff, and now I can't even get in there! Sad


Wiring loom is pretty much finished, was only a little soldering and tidying to do and had to add a wire for the front brake switch as there just wasn't one Confused

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP_0675_zpsd1329a37.jpg

I feel your pain about having a car stuck in your garage, if it's not something that will gain value in time though you sometimes just have to cut your losses.

The car in the garage is a mk1 MR2 that did used to be my pride and joy but I must admit I am ready to part with it now after not using it for so long, I just want my garage back now really.
It doesn't owe me anything, I paid £2200 cash for it 15 years ago, I've definately had my moneys worh out of it and it's worth around 4k now.
My delay in getting round to selling is more due to finding the time, it needed a few small jobs doing and an MOT putting on it. It is ready for sale now though... so if you're interested...... Very Happy

https://i9.photobucket.com/albums/a75/RS1Rebuild/mr21_zps9624f971.jpg

https://i9.photobucket.com/albums/a75/RS1Rebuild/mr22_zps1035c797.jpg

Was hoping to be cracking on with the bike this morning but we've got rain!
I think I need to invest in a gazebo.... or sell the car! Very Happy
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Just_James
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PostPosted: 12:27 - 30 Aug 2014    Post subject: Reply with quote

The day is looking up! Some goodies have arrived! Very Happy

New grips and lots of shiny new bolts, washers and nuts and things... I haven't counted them but think they're all there Very Happy

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP_0676_zpsb93e7394.jpg

Getting quite excited now... especially as I'm at a stage where there isn't a single bit of the bike left that's covered in dirt, oil and grease - it's all nice clean bits to work with Cool
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stevo as b4
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PostPosted: 18:08 - 30 Aug 2014    Post subject: Reply with quote

Your doing a great job on it so far dude!

And that Mk1 MR2 must be the cleanest modified one I've ever seen too!
They are a real fun little car to drive and as you say they have been appreciating steadily for a while now, so you've done well by keeping it so long.

https://i1070.photobucket.com/albums/u482/stevo1994/001.jpg
I'm waiting for this to appreciate, but really should be getting it back on the road this year as it's not that bad to drive (handles better than a std one anyway) and I think it's genuinely a better car than say an Escort RST, but I'm just waiting for it to be worth as much now! Laughing
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Just_James
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PostPosted: 19:01 - 30 Aug 2014    Post subject: Reply with quote

Cheers mate. Rover looks good, can't remember the last time I saw one on the road. Does look like you've put some money into that!

Not been able to get much done with the bike today as it's been raining on and off all day. Did manage to do a few bits though.

Have finished respraying the yokes, have decided the forks will be going gold so have done these to match

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP_0663_zpsa3119b00.jpg

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP_0677_zps49ba8376.jpg

Have finished repairing the front mudguard and got it in primer.

The two rear bolt holes were non existent so I had to fabricate them, there was also a crack in it and both the other bolt holes were damaged too (was obviously ripped off the bike at some point) so had a bit of work to do on it.

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP_0658_zpsfbef4836.jpg

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP_0659_zps5ba7fc2e.jpg

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP_0678_zps82e0cef4.jpg

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP_0679_zps14b8f982.jpg

Have also started rubbing down the wheels ready for paint. These aren't the ones that were on the bike but came with a job lot of spares I bought - they were in slightly better condition than the others and the tyres are literally brand new so decided to use these.
Most of the hard work is done with these now, I got rid of all the corrosion etc and got them in primer last week - just got to finish flatting the primer now and then I need to decide what colour they are going Thinking


https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP_0684_zpse19b79b9.jpg

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP_0685_zpsad27a93e.jpg
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MattWadz
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PostPosted: 22:12 - 30 Aug 2014    Post subject: Reply with quote

What are you using to paint those parts! :O looks better than factory!
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P.
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PostPosted: 23:11 - 30 Aug 2014    Post subject: Reply with quote

Doing a good job of this. Thumbs Up
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Just_James
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PostPosted: 00:53 - 31 Aug 2014    Post subject: Reply with quote

MattWadz wrote:
What are you using to paint those parts! :O looks better than factory!


Bits like the yokes may look 'better than factory' (thanks! Very Happy ) as I've taken a bit of time to sand out the casting marks and then hit with a 2k high build primer and flatted again to remove the original mottled finish and any other imperfections to make smooth. The gold is actually just a couple of coats from an aerosol (£3 from local hardware shop) then clear coated in 2k, it's not difficult to get a decent finish on little bits like those with a little prep'.
Forks will be done the same to remove that mottled finish and make smooth before basecoat and clear coat.

I'm working in far from ideal conditions having to spray outside and have flys and leaves etc that come looking for fresh paint but I can mostly get away with it for bits and pieces like those, if I've not got my garage by the time it comes to paint the fairing and tank though I may have to look at borrowing somewhere for a few hours to spray those
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Just_James
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PostPosted: 21:03 - 31 Aug 2014    Post subject: Reply with quote

Tank is in primer! Very Happy

The tank didn't actually look all too bad on the outside with a couple of minor scratches etc but when I took the fuel cap off.... different story! It was absolutely rotten in there!
Took the tank off a while back and unfortunately don't have any pics to show but when I drained it you wouldn't believe the cr@p that came out! There was more water than petrol in there and about an inch of thick sludge and silt had settled in the bottom completely engulfing the fuel filter - how it was running is genuinely a complete mystery!!

After lots of flushing out I finally got every last bit of crud out of there and started work on the filler neck.

I don't have a picture of the state of it before I started rubbing it down but you get the idea

https://i9.photobucket.com/albums/a75/RS1Rebuild/tank2_zpsd458e963.jpg

https://i9.photobucket.com/albums/a75/RS1Rebuild/tank4_zpsa11607e7.jpg

After this stage I got in with the dremel and managed to get it back to good metal, few little rust spots left were treated with jenolite and I was ready for primer

https://i9.photobucket.com/albums/a75/RS1Rebuild/tank6_zps8b1414db.jpg

https://i9.photobucket.com/albums/a75/RS1Rebuild/tank7_zpsf7e62bca.jpg

Another job off the list Very Happy
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PostPosted: 22:49 - 31 Aug 2014    Post subject: Reply with quote

Some really nice work there, James.

I like the MR2 too but unless I shrink a few inches in height I'm not going to be able to offer that a home.
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Just_James
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PostPosted: 23:44 - 31 Aug 2014    Post subject: Reply with quote

Thanks mate Very Happy I'm chipping away at it... one of the difficult things to do is decide how far to go with each thing - I tend to be a bit of a perfectionist and don't like doing things by halves but have to be realistic with what really is worth doing. I like to think I'm striking a balance with this one and ultimately I have a max budget to stick to so that will largely command just how far I go with this little project!

How tall are you to not fit in an MR2? Shocked

There's plenty of room in there and if you feel things are a bit tight you can just pop the roof off - it's a T-bar! Very Happy

....so you're all out of excuses now! Will you be paying cash or cheque? Very Happy Very Happy
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PostPosted: 13:36 - 01 Sep 2014    Post subject: Reply with quote

Just_James wrote:
Thanks mate Very Happy I'm chipping away at it... one of the difficult things to do is decide how far to go with each thing - I tend to be a bit of a perfectionist and don't like doing things by halves but have to be realistic with what really is worth doing. I like to think I'm striking a balance with this one and ultimately I have a max budget to stick to so that will largely command just how far I go with this little project!

How tall are you to not fit in an MR2? Shocked

There's plenty of room in there and if you feel things are a bit tight you can just pop the roof off - it's a T-bar! Very Happy

....so you're all out of excuses now! Will you be paying cash or cheque? Very Happy Very Happy


I looked at buying a MK1 about 12 years ago but had to go for a MK2 in the end as there was just not enough room in the MK1 for my knees. I'm 6'4" with 34" legs and although it was driveable I couldn't have lived with the lack of leg room.
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skatefreak
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PostPosted: 16:24 - 01 Sep 2014    Post subject: Reply with quote

What did you use to rebuild the damage on the mud guard?

Doing a really good job so far Wink

-Jvr
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Just_James
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PostPosted: 16:56 - 01 Sep 2014    Post subject: Reply with quote

Thanks mate.

For the bits that were missing I used a combination of fibreglass and chemical metal.
I basically used some fibreglass bridging compound to get the basic shape, I looped some masking tape around it to help give me the curve. Once that was cured I buzzed it down and skimmed over the whole repair with chemical metal to give it the strength and build the area up, then just sanded that down to shape and drilled the holes.
It's not pretty on the underside but it does the job Very Happy
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Just_James
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PostPosted: 21:23 - 01 Sep 2014    Post subject: Reply with quote

Most of the plastics are repaired and in primer now.

The tail section had a bit broken off, all bolt holes except one were broken out and there were around 10 holes around the rear seat section where previous owner had made multiple attempts at attaching a piece of tin with self tappers to cover the battery Evil or Very Mad

So a few fiddly bits of fibreglassing to do on this but am there with it now

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP_0691_zps74570153.jpg

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP_0690_zpsb32586aa.jpg

The nose fairing was in quite a state with the wost damage being on the o/s and all that flaking paint to deal with!

https://i9.photobucket.com/albums/a75/RS1Rebuild/IMG00080-20130807-1324_zpsc6c77133.jpg

Fibreglass was out again for this to piece in the missing bit and reinforce what was there. Also filled the indicator holes to keep my options open for indicators - will obviously just re-drill them if need be.

https://i9.photobucket.com/albums/a75/RS1Rebuild/frontfairing1_zps4a851ec7.jpg

The repair to the o/s should only really be noticeable from the inside due to it missing the ridge in that area but I will be painting the inside of it matt black once it's rubbed down so shouldn't be too noticeable at all

https://i9.photobucket.com/albums/a75/RS1Rebuild/frontfairing4_zps5b651934.jpg

Just nice to see it in primer now and without all that silver paint hanging off it!

https://i9.photobucket.com/albums/a75/RS1Rebuild/frontfairing2_zps50341e7a.jpg

https://i9.photobucket.com/albums/a75/RS1Rebuild/frontfairing3_zpsa7c3d8d6.jpg

The side panels I bought weren't in too bad condition with just some cracks around the belly and some scuffs and scratches - now also repaired and in primer

https://i9.photobucket.com/albums/a75/RS1Rebuild/DPP_0686_zpsf09aad3a.jpg

As far as plastic go, I've only got the hugger to do now and that's no big job as it's the only bit that doesn't need fibreglass! Very Happy
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Just_James
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PostPosted: 17:32 - 03 Sep 2014    Post subject: Reply with quote

_Iain_ wrote:
Really impressive work.

Hope this turns out the way you were hoping Smile Thumbs Up


Thanks mate Smile

My plans for it have changed several times now for various reasons but it is mostly going standard / original and should end up looking something like this but with gold forks and different coloured wheels. Haven't decided what colour to do the wheels yet but they have needed a lot of work and don't want to have put all that time in just do them boring old black or silver (though black does suit it I must admit) Thinking

https://www.50cc-motorcycles.com/pictures/rs1-01.jpg
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