#42 Ollie and Steve GD's 2008 DD Bike Preparation

[CK & AK]

Have you checked the heads yet Steve? (measure the valve diameter)

[Steve GD]

Not yet. C (...or A?). We are planning to make those checks once the engine is out and on the bench.

[Gilps]

[quote=Steve GD;124502]
ZDM 600 AZC 000145

quote]

That means it was originally a 583cc engine, number 145 off the production line, so a very early one. Mine is 4 hundred and something. It started out life as a 583 but someone may have played with it judging by your dyno figures.

[Ollie]

Originally Posted by Steve GD

Ok....more progress....

As is normal in cases where a machine made of different materials has been allowed the time for corrosion to set in, some of the components needed considerable ...erm... persuasion to come apart . The enthusiasm with which Ollie addresses these challenges is just a tad scary. I can vouch for the fact that , at least in the matter of nut removal , Ollie's special government training has not been wasted.

We have drained the oil (all 1.8 litres of it...as much as would come out) and cut out the two short pieces of strip steel on the frame (one each side) to which the side fairing standoffs attach. These had been damaged in the accident which caused the bike to be offered for sale as a potential race bike, and will have to be replaced before the frame is repainted.

Ha ha its great fun, no NUT IS EVER TO TIGHT! They just need persuasion!! some a bit more than others!

That bloody sump plug was the Tighest! but it caved eventually!!

And talk about making an easy job of those fairing supports, the Air Grinder is top for that!! Right so Tonight i am out in the Garage practising my welding, and finishing making the new brackets..

i may just linish the frame up too where the otd weld is still on....

[998gsb]

Originally Posted by Ollie

Ha ha its great fun, no NUT IS EVER TO TIGHT! They just need persuasion!! some a bit more than others!

That bloody sump plug was the Tighest! but it caved eventually!!

And talk about making an easy job of those fairing supports, the Air Grinder is top for that!! Right so Tonight i am out in the Garage practising my welding, and finishing making the new brackets..

i may just linish the frame up too where the otd weld is still on....

So if you are making brackets again Ollie - I guess that means that they'll be ready in about June 2008 ???

[nogaromill999]

Not that soon Gav, I'm still waiting for some rearset drawings that were GOING to be ready in June 2006 !

[Ollie]

Originally Posted by 998gsb

So if you are making brackets again Ollie - I guess that means that they'll be ready in about June 2008 ???

1 already made mate lol

[Steve GD]

OK....more progress....Swingarm and forks removed and engine out and on the bench. The frame has been tidied up (welds ground off) and degreased ready for paint stripping and refinishing.

Not sure what we are doing with the swingarm, yet but the rear shock will be one of the many bits for sale soon. The forks are like a pogo stick at the moment...no damping at all ....but they will be refurbed with new springs, oil and seals if the other components check out ok.

Having got the engine out, no further work has been done on it...rest assured I will post when we know the internal dimensions. I'm not obsessive about this. I know I'm not. Really.

OK, so now , with the exception of the engine, all the components are small/light enough to lift with one hand. All to be cleaned, fettled, rebushed, adjusted, painted etc and reassembled. Just like a jigsaw, really.

The next steps will be to get the frame painted and to check out the engine.

OK, that's all for now....I'm going to be away in Germany for a few days, so no more updates from me until the end of next week.

[Ollie]

Right you Orrible lot, i have had some good progress this week, but sorta got stopped last night from going to far as need to get something checked out, see the last bit of this post...

Right we left you knowing the bike was in lots of manoverable bits like a jig saw, this is the case still but things have developed.

the frame is now just that a Frame and has nothing on it, i ground out the brackets that the fairing supported from as they were had it, i have now preped the area and its ready for new ones to be welded in. (see below)



and here are the new brackets placed in position (this is actually not the one i used it was a bit out so made other ones)



right so now with my brackets made i need to get them welded in place, NO PROBLEM bit os sizzling later and here we are







Right they were not to easy to weld in as they didn't wanna take to the frame, (think the origional painting process had left something in the frame material) only one way to sort that and it was to really crack up the Ampage, (good job we have a Top Butters Welded to sort this) it sounded like i was playing with a lite saber!!

As you can see my welding is not the best, but it was plenty good enough for the job, i really stacked the welds so that i could dress them up after better, as seen in the next few pictures.









I had also forgot to add that i have used a load of Nitro Morse on the frame to remove the existing paint, not with much luck,

So i had an early start this morning, and took the frame, Top Yoke, and belt covers to be sand blasted, what a top job was done (sorry i do not have pictures)
I picked these up after work and headed straight to the Powder coaters ( a mate of mine) so that is where the above bits are awaiting there new clothes, colours and pictures to follow in the next few days.

As i mentioned above i was planning on doing more, but got stopped as i was unsure due to some findings,

My plan was to also last night strip my Forks and replace the Std internals with Linea Wilbers ones and the uprated oil, and also new seals, but whilst i degreased them , i decided to check the chrome sliders for any damage, and wear, (which i have found so advice is needed if they are worth using or should be replaced??? suggestions please)



this one shows the patch the best, just below the dust seals, what do you think? should i need new forks??



Also upon further closer inspection, right down near the fork bottoms i noticed some pitting in the chrome, like small stone chips, will these be alright?
i dont think the pictures are the best sorry.





Well i will not get much more done for a few days, but hope to have painted parts back very soon....

thanks for reading!!!

[Ghost]

Perhaps you may get them rechromed there is a place in Coventry called the Standard chroming and plating Company its in Cross Road they will be able to help I'm sure.

Right!! not being unkind here just good advice.

Do not go welding anything that is safety critical as looking at your brackets its not the best. The weld is too cold, has no flow to the weld material and very little penetration.


Phil

[Steve GD]

Originally Posted by Ghost

Perhaps you may get them rechromed there is a place in Coventry called the Standard chroming and plating Company its in Cross Road they will be able to help I'm sure.

Right!! not being unkind here just good advice.

Do not go welding anything that is safety critical as looking at your brackets its not the best. The weld is too cold, has no flow to the weld material and very little penetration.


Phil

Phil, thanks for the advice. As you have sussed, the purpose of these brackets is to hold the fairing in place , so non-critical as far as safety is concerned. All we are hoping for here is to better the strength of the original...not hard as it was a piece of 1.5mm strip sh1ttite.

[Ghost]

I did realise that Steve and did not wish to appear condecending. But as a qualified welder, I felt I have the expertise to offer constructive criticism. Its all about guidance and practice, everyone has to start somewhere.


Phil

[Steve GD]

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Just got some bits back from the powder coating folks si I thought I'd post a couple of pix....
Given how far forward David is in his prep, makes it seem like we still have an awfully long way to go....still....we still have plenty of time.............................don't we?

[nogaromill999]

Looking good....you have to remember Steve, i didnt strip mine down as far as you so I'm bound to be further ahead....that doesnt mean I will be on the track though !

[Duke of Wales]

Hope you did'nt pay for that welding job , got to up there with the worst i've seen !!!!!!!!!!!!!!!!!