SuzukiSavage.com - Double RYCA build Mar 2019 updates

Gyrobob

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Re: Double RYCA Build
Reply #45 - 05/25/11 at 13:34:14

On 28 April, 2011, we started on the tanks. It took a bit of patience and elbow grease to get them ready to paint. First we had to strip off the stuff that RYCA left stuck on the outside.

We chose to take it off mechanically, rather than chemically, using a sharp chisel and various wheels in a drill.

Don't remember this dent being there before,......

One down, one to go,....

After cleaning the tanks, we were worried about how to protect the underside of the tanks where there are some layers of metal with a little bit of airspace between. (The forward and aft tank mounts) We couldn’t even determine what kind of shape those surfaces were in, let alone get in there to paint them.

One worry was that whatever RYCA used to partially strip the paint off the tank might still be stuck in those cracks. (acid?)

We squirted a lot of metal prep solution in there with several repetitions of rinse/compressed-air-blow-out to kid ourselves into thinking we got the mostly-hidden surfaces free of whatever left over gunk was left in there.

Then several water rinses. (each followed by a compressed air blow out)

Then several alcohol rinse/compressed air repetitions. Alcohol combines with water and dries real fast, and leaves no film. We let the tanks sit out in the sun for several hours to make sure those hard-to-get-to surfaces were dry.

Then we used some watery white primer Bob had laying around and sprayed that primer into all those surfaces, soaking them to the point of the primer running off in a stream. We let them sit out in the sun some more and dry overnight before doing anything else. Now we estimate those “hidden” surfaces have a coat of primer down in there, hopefully preventing any long-term corrosion. Done on 29 April.

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« Last Edit: 09/30/11 at 07:07:10 by Gyrobob »

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MotoBuddha Serious Thumper Offline Let's roll! Posts: 1416 Charlotte, NC	Re: Double RYCA Build Reply #46 - 05/25/11 at 15:03:43 Good work, but you need to check your calendar.
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Gyrobob Serious Thumper Offline Posers ain't motorcyclists Posts: 2571 Newnan, GA Gender:	Re: Double RYCA Build Reply #47 - 05/25/11 at 20:03:35 Calendar?
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Gyrobob Serious Thumper Offline Posers ain't motorcyclists Posts: 2571 Newnan, GA Gender:	Re: Double RYCA Build Reply #48 - 05/25/11 at 20:50:01 On 30 April thru 2 May, we spent several hours on the tanks. Cleaning the surfaces, bondo, spot filler, primer, bodywork files, sanding blocks, and packages of wet/dry sandpaper used wet. Not an insignificant effort. [size=14][/size]
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MotoBuddha Serious Thumper Offline Let's roll! Posts: 1416 Charlotte, NC	Re: Double RYCA Build Reply #49 - 05/26/11 at 05:24:44 Very diligent body work. It's going to look great. But are you missing something?
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Gyrobob

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Re: Double RYCA Build
Reply #50 - 05/26/11 at 05:33:44

OH MY GAWWWWDDDDDD!!!!!! We ain't got no way to get the gas outa the tank!!

Hey, I know,.... we'll fabricate a gas cap with a hole in it so we can run a hose from inside the tank that goes all the way around to the carb. The hose will go from the bottom of the tank, up thru the cap, and then outside the tank down to the carb, which is lower than the bottom of the tank. Once we get a siphon action established, we are on our way!!

Pretty simple and reliable, eh? No moving parts. Instant gas gauge. Bottom side of the tank all clean and streamlined looking.

Hey!!!!! This could really be something! An accidental discovery to better the miserable state of mankind,.. it'll rank right up there with saccharin, microwave ovens, dynamite, post-it notes, teflon, and penicillin.

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« Last Edit: 05/31/11 at 13:03:26 by Gyrobob »

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Gyrobob

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Re: Double RYCA Build
Reply #51 - 05/31/11 at 10:48:40

We know this post is out of sequence. ahem..

On 17 April we cut off all the stuff as per the RYCA video. http://www.youtube.com/watch?v=2CyrSeBtG1Y

Not very hard to do. We were conservative with the cuts,...meaning we left a little extra on each cut so we could grind it down to the exact dimension.

We used all kinds of cutting machinery.
The drill with the skilsaw-cutoff-wheel-too-small-for-the-saw-anymore wheel worked okay. It is handy for evening things up.
The skilsaw is overkill. If it is all you have, though, just take it easy, and be careful. The thing is so powerful, you could make a cut that was a BIG mistake really fast, or,.. worse yet,.. hurt yourself.
The welding grinder with a cut-off wheel goes through the frame like a hot knife through butter,.. so if you are in a hurry and/or have a lot of frames to do, AND you can control the thing accurately, have at it! More controllable than the skilsaw, but almost as powerful.
A plain old hacksaw would probably get all the cuts done in an hour or so.
Turns out a simple little dremel tool with a cut-off wheel works pretty well. It is a lot easier to make precise cuts, and the frame metal is plain steel (fairly soft) so the dremel cuts reasonably fast. You'd probably use up only a couple of wheels for all the cuts on one frame.

One thing we have yet to do is to tidy up the cut surfaces so they are clean and perpendicular.

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« Last Edit: 05/31/11 at 18:07:22 by Gyrobob »

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28996 L.A. California Gender:	Re: Double RYCA Build Reply #52 - 05/31/11 at 11:15:39 Hmmm... cutting edge technology... I like!
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Gyrobob Serious Thumper Offline Posers ain't motorcyclists Posts: 2571 Newnan, GA Gender:	Re: Double RYCA Build Reply #53 - 06/05/11 at 07:58:58 RYCA tells us we have some boxes on the way!! Maybe we aren't too far from having some CS-1s coming alive.
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Gyrobob Serious Thumper Offline Posers ain't motorcyclists Posts: 2571 Newnan, GA Gender:	Re: Double RYCA Build Reply #54 - 06/07/11 at 15:00:01 UPS says the boxes are in Peachtree City, about 10 miles away. Maybe tomorrow!
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Gyrobob Serious Thumper Offline Posers ain't motorcyclists Posts: 2571 Newnan, GA Gender:	Re: Double RYCA Build -- Boxes arrive Reply #55 - 06/07/11 at 20:32:51 Well, well, well! Guess what showed up today,....120 pounds of stuff from RYCA.
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Gyrobob Serious Thumper Offline Posers ain't motorcyclists Posts: 2571 Newnan, GA Gender:	Re: Double RYCA Build -- unpack everthang 8 May Reply #56 - 06/20/11 at 13:12:01 It's Christmas! I waited a day to unpack all the stuff so Jud could be part of the event. Then we took inventory. Fun. We had some prep stuff to do before we actually started buiding cafe racers. Carbs, paint, and, unfortunately, wheels.
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sbaugz Ex Member	Re: Double RYCA Build -- boxes arrive 7 May Reply #57 - 06/20/11 at 16:16:30 nice. Can't wait to see your build. Mine is currently stalled, waiting for the painter.
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Gyrobob

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Re: Double RYCA Build -- boxes arrive 7 May
Reply #58 - 06/20/11 at 16:48:21

We are doing our own painting. Corvette colors. Jud's is dark metallic blue, mine is dark bowling green metallic. They look almost black until some sort of bright light is on it.

Neither of us have done any real painting aside from aircraft painting while working on A&P certificates, (forty years ago for me). We're using Dupli-color because it is so easy and cheap. Just get the surface smooth,... which was no small task on the RYCA tanks. Then prime with scratch-fill sandable primer,.. maybe three coats with a light wetsand of 400 grit in between. Then a few color coats with light wetsand, followed by a few coats of clear. Wet sand with 2000 grit for a bit, then after some rubbing compound and some polishing compound it looks remarkably good.

The whole cost for two bikes will be less than $100.

UPDATE September 2012:
-- Less than $100,.. dream on.
-- Duplicolor clear disintegrates when gas hits it. Use Duplicolor Engine Paint Clear Gloss instead. After it cures for a couple of weeks, is rubbed out, and waxed, it can take a brief sprinkle of gas just barely. If the surface gets soaked with gas, you'll have to let it dry for a day or two, then rub it out. Apparently the only way to get a gas-proof surface is to use two-part automotive paint that has to be mixed and sprayed on within an hour or two.

UPDATE September 2013:
-- Less than $100,.. dream on. (still true)
-- Duplicolor clear disintegrates when gas hits it. ~~Use Duplicolor Engine Paint Clear Gloss instead.~~ There aren't any single ingredient paints that can handle even a brief gas spill.

"Apparently the only way to get a gas-proof surface is to use two-part automotive paint that has to be mixed and sprayed on within an hour or two." Still true.

I'll be finding someway to clear coat this stuff with gas proof paint. Either Spraymax 2k or have a real paintshop put on a proper clear coat.

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« Last Edit: 09/13/13 at 06:17:46 by Gyrobob »

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sbaugz Ex Member	Re: Double RYCA Build -- boxes arrive 7 May Reply #59 - 06/20/11 at 17:59:05 wow, great job using those spray cans. Very smooth and glossy finish you have there.
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