First Generation Ascots > The Thumper Years: Modified To Full Customs
Dutch FT project
J6G1Z:
That looks real nice!
When it comes time to start the engine, you might consider gently heat cycling the paint. Start the engine & then shut it off as soon as you feel warmth. Let cool completely & then repeat several times while allowing the engine to become warmer each time.
It will probably stink like paint fumes for a while until all the solvent is cooked out of the paint.
J.
FT500R:
Will definitely do that.
The paint I used is not an official heat resistant paint so it will smell quite a bit I think. I've seen it used on many (air-cooled) engines though so it can handle the heat.
I've added a picture of a mock-up of the other side of the engine in the previous post.
I'm now ordering stainless steel bolts but I ran into a small problem. Honda uses 6mm bolts for almost everything but somehow they decided to use 7mm bolts for 2 of the 13 bolts in the valve cover. 7mm bolts are very hard to find so that's a small issue. (Can't have 2 ordinary bolts while I replaced all others with nice stainless steel ones...)
FT500R:
The mailman came to my door again
Some small original Honda parts (tacho cable delete and oil filter) and a whole shitload of stainless steel bolts.
I've spent yesterday evening prepping all covers for reinstalling. Had to remove a lot of old gasket, sand the surface area, determine which bolts go where (have an Excel file with pictures if someone is interested) clean up the threads of some of the mounting holes etcetera.
A rather tedious job but it atleast means I'm getting closer to assembly which is always nice.
I've also replaced all bolts in the carb and found a way to mount the throttle cable bracket without it hitting the cilinder head.
I'm going to sand the cooling ribs on the cilinder and head tonight so hope to be able to post some pictures of that soon.
FT500R:
The result of sanding the cooling ribs and mocking up the engine again:
The other side
I also ovaled the mounting holes on the harley inlet manifold to use is on the FT
This puts the carb nice and close to the cilinder (and now the carb sits straight so it's easy to mount a big open air filter)
You do have to alter the throttle mounting bracket a bit though (you need to grind away a bit at the bottom so it can tilt a bit further)
I still have to tidy up the bracket itself ofcourse
Next step is get some liquid gasket and then close the engine for real.
FT500R:
Unfortunately I ran into the exact problem that a lot of FT's have.
Stripped cilinder head cover boltholes :(
When pulling them to the prescribed tension 3 of them snapped through.
This are the culprits:
I probably have to get a Helicoil thread repair set and rework most of the threads.
To relieve some agression I got my grinder out and started working on the frame.
Removed some small brackets that I didn't need anymore and cut the back of the frame
cut up frame
The bike looked as follows with the cbr900rr forks and xs650 front wheel, standard rear shocks and rear wheel.
Next I mounted the longer shocks and the BMW wire wheel that I still had.
How the seeting position will roughly be.
A day with some ups and downs. Glad with the look of the bike with the wire wheels and the shocks. Not so glad with the stripped bolts ofcourse
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