G/S Rebuild (The Rebuild of Fred)

[steve brown]

So I've decided to find a G/S and try to get it back to as near as original specification as possible. I finally found one through the forum from fellow tosser Gadget. We exchanged many emails and PM's about G/S and about rebuilding the bike. I've decided to name the bike Fred as the Mrs thinks I'm starting to look like Fred Dibner in my overalls.
So finally picked up Fred from Gadget, I've been waiting to get the g/s since christmas and had a long trip to Norwich from Herne Bay. Me and Gadget loaded up my pickup full to gunnels and then spent time with Gadget going though all the things that had been done and the things that needed doing. Luckily for me the frame, foot rests and some engine parts Gadget had had powder coated.I wanted to get back to kent before the rain which had been forecasted begun as the back of the truck is a bit open plan. I wanted to get to Gray's engineering and had arranged with Jim to put the frame on his jig and make sure its straight as I didn't want to get going and find out that its bent. Anyway got down to Jim's just as the skies opened up,and had a mad five minutes getting the frame, pots, gear box and bevel box off to have them bead blasted. So this Sunday I spent morning filling the workshop with what's left of Fred and sorting out where to start when I get my frame back from Jim. The picture below is of the bike (Fred) before being dismantled.

 

[(RIP) Tunneruk]

Hi Steve,

That's a lovely looking project fella, I look forward to watching your progress. If there's anything I can help you out with don't hesitate to get in touch

 

[Trekker3]

I could be persuaded to have one of these, must be something to do with my age

 

[steve brown]

A little up date. I got the frame back from Jim Cray today and good news the frame is nice and straight so now I can start putting it back together. I put the stand on and wanted to fit steering bearings but they seem to small? I know you can heat the bearings up but they look to be miles to small. I might give moterbins a ring tomorrow to see if the code is the right one for my model (the box says challenge 30205)?. Any way someone's wrote in felt tip pen, g/s steering bearings on the box?, I just don't want to start bashing them on and bugger them up. I think I'll wait a bit unless anyone has any advise to offer?.

 

[Tinytim]

I'm in.

 

[DrAlf]

Why are you rebuilding it? Looks perfectly fine in the first photo - or am I missing something? Nice bike.

 

[steve brown]

Hi dr alf well the reason I'm building Fred is I brought it all in boxes and I would like to build it back as near as I can to being original bike with luck .

 

[newboy]

Hi dr alf well the reason I'm building Fred is I brought it all in boxes and I would like to build it back as near as I can to being original bike with luck .

Ahhh - you mean Gadget dismantled it?

 

[steve brown]

Found out why bearings wouldn't fit wrong size got hold of motorbins checked sizes over the phone the ones that came with the bike were to small so glad I didn't false them on more than likely messed on the thread . So If I can them before the weekend I should be able to get a bit of a move on hope so.

 

[steve brown]

Its been one step forward and to back this week finely got the right steering bearings though the posts on thursday and they went on lovely ,then I thought I better check the forks are not bent before I putt them back on .So I nipped up to Jim gray to see if he could quickly putt his gage on them ,we'll they weren't bent but they had some nasty gashes in and just wasn't worth getting them back on and then start leaking so now they got to go off for repair could have don't without that.Anyway I was bit stuck with what to do so ended up cleaning up the old engine bars and the pump that came in one of the boxes managed to get a coat of primer on them and ended up fitting the foot rests and rear frame.

 

[steve brown]

We'll finely got the new clutch in at last.Still waiting for forks to be chromed so haven't had much to do lately ,we'll saying that I've been lucky that managed to use my mates bead bluster to clean up gear box heads and anything I think needs a clean . Also have taken all the bits off the old engine and fitted them on .looking at the heads I think I might get the valves guides done as looking bit naff have to see how that would cost ?

 

[steve brown]

New pictures and update

We'll got going this weekend with top side of engine ended up having to fit new guides and valves and rocker arms the arms where so pitted just wasn't worth sticking them back sort of came this far hay ho ? And still waiting for forks to come back they now saying one more week bloody annoying though .Couldn't wait to fit engine I know it's more likely to be easier with the wheel s on but it's another weekend gone so went for it ,nearly gave myself hernia getting it in and kept wiggle it about on some blocks of wood in went in a treat so in the the week get gear box and drive back on and wait for my forks .?

 

[steve brown]

At last got the forks back from being chromed and the rear shock all arrived this Thursday ,so got cracking this weekend first assemble the forks new seals fitted .Put handle bars on which I sprayed but I must say slightest touch on the paint makes a mark even though I gave a good coating of lacquer? Pleased with the rear shock looks nice in red bit of contrast I think. So this week going to tackle the electric's also a trip to my mates spray shop this week with the tank mud guards and panels .As seen in photos got Fred out the shed nice to do a bit of tinkling in the sun .Well at this rate il be on the road soon ,quick question would anyone know where I could pick up a pair of panniers frames that would fit the g/s ?

 

[jackassdave]

my love for the airhead has been rekindled

 

[tuftywhite]

That is coming along beautifully.

Keep coming with the pictures.

 

[steve brown]

G/s rebuild

Finally managed to get the wiring done with a lot of head scratching got so stuck on some of it . Lots of phone calls to Jim cray for help I think he got fed up answering the phone in the end he suggested bring the the bike up,as he had a g/s in and I could copy from it which made life a bit easier well that fine until a came to wiring up the Enduralast alternator bloody to difficult for me .So had ask Jim to help which he didn't really have time to help but standing there for half hour he finely gave some help ,I certainly wouldn't have worked that out . Loaded Fred back on the trailer got in the garage for next step strip down carps and fit new seals diagram and a good clean and fit my lovely polished exhaust . All fitted back together put on a old tank ready to start up well Fred burst in to life but run so rough and wouldn't tick over so striped the carbs down again and more carp cleaner and another go still won't run right ? Back on phone to cray engineering for more advise he suggested checking jets again he was right one jet 143 and the other one was 148 so ended up buying new ones .With new jet ready to go on my knees fitting them on ,with the garage door up a voice from the drive said I've got to of those and can I have a look at the bike so this old boy came up the the drive with his dog asked what I'm doing I said I'm trying to balance the crabs so still hanging on to his dog he picked up a screwdriver and got them perfect and then went on to give me loads of tips .Next stage pick up tank mud Guards and panels from spray shop I'm :getting closer

 

[steve brown]

Up date

I think I'm there at last been a bit slow to get finished with work taking over for last couple of weeks ,but just couldn't get the carbs to balanced anyway after striping them down time after time I discovered that the carbs weren't a pair so on wonder I struggled to get it running right . Anyway picked up a carb last week fitted that and pressed the starter and Fred run as sweet as a nut ,all so pick a set of fog lights from ebay in German wired them up over the weekend ,played around with the brakes as I seemed to have not back brake after I shot down the drive for a little test ,nearly ended up in the car parked across the road so taken up the slack on the rod and another run down the drive not so fast this time but brakes felt ok but not brilliant any way I've all ready booked Fred in for mot today .Picked up after work and no problem with mot so getting road tax tomorrow can't wait for end of mouth to go for a ride out .next little job is get a set panniers I'm going for hepco as my last set were well made and I like to tour a bit and the standard for r80 won't take all my gear. And lastly I won't to say a big thank you to gadget for letting me takeover the rebuild ?i wished I was there when you striped it down it was a struggle with boxes of bits and pieces and having to work out we're they come from anyway thanks Jhon and Pete Kay's for letting me have the old tank at a good price .and Jim cray for tips tools and the bloody electrics I got so stuck with .So that's Fred just about done now I think I've got the bug now for another one next winter if I'm allowed ?Also is there a touring screen that fits the bike ?

 

[tuftywhite]

Some photos please. All of the other photos have been great. It would be good to see the finished bike.

 

[steve brown]

Hi tufty got gremlins on photos at moment working on it?

 

[steve brown]

photos

il put some more on soon now my computer going again