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Black Beauty goes to the SPA for a make-over

Posted: Sun May 19, 2019 5:29 pm
by Easter
Some of you with long memories and too much time on your hands may recall a project I started two or three years ago entitled Black Beauty (named with tongue in cheek!). To briefly summarize, the bike was given to me by a friend of a friend who had inherited from a deceased brother. The bike came with the most elaborately detailed service record I have ever seen dating all the way back to pre-history (sometime in the mid-'80s) when first acquired by said brother. To put it mildly the bike had seen better days but unlike most of the bikes I acquire it was complete and still assembled. In fact it was so complete that in addition to the usual tupperware front and back it also included a siren and blue plastic air horns. The original mufflers had been replaced by welded on "cherry bombs" intended for the teenage hot rod crowd and the shelter and side panels had been painted with Rhino Liner then painted blue. A lovely combination.

New belts, new oil, new filters,battery and plugs and she started up. Not good but she started. I had a set of fresh GL1000 carbs setting on the bench for a project that I was working on so I installed those just to see how it would act with more or less decent carbs. Ran fine. I rode it around the neighborhood and to the gas station putting maybe twenty miles on, then parked it, removed the carbs and battery and there it sat in my car port for the next two years.

My plan all along was a restoration. The bike was titled in my name so I naturally thought I would keep it, maybe.

Now that I am wrapping up Red Belly, it is Black Beauty's time to shine, or what ever.

Re: Black Beauty goes to the SPA for a make-over

Posted: Sun May 19, 2019 5:42 pm
by Easter
I don't recall for certain, but I am pretty sure I rebuilt the brakes but they were frozen up again and had to be pried off in order to roll the bike into the shop. Friction was still so strong, I had to use the hoist to get the bike onto the lift. But lift I did and after fiddling with the brakes and installing the freshly rebuilt original carbs and a new battery (and for those keeping track, a new solenoid and jumper wire at the clutch) and she started right up and sounded good. A few minutes of run time and the smoke cleared.

So then the tear down, yesterday afternoon I got as far as the only the engine and front forks still attached to the frame. Today the frame came off the engine and the front forks as well. So now it is Spa time, just as soon as I pull the power washer out.

Re: Black Beauty goes to the SPA for a make-over

Posted: Mon May 20, 2019 10:49 am
by Jonesz
Well Easter looks like you have some fun ahead of you. Looks like you will have a few takeoffs to advertise as "Rat Rod" parts. The PO must have been a bit of a character! Will enjoy watching your makeover on this one.

Re: Black Beauty goes to the SPA for a make-over

Posted: Mon May 20, 2019 3:52 pm
by Pedrotq
Love that cigarette lighter :lol:

Is the front indicator broken or was it fixed to point out to the side???

There is a certain sense of achievement bringing a piece of equipment back to its original designed state after someone has put their personal taste and workmanship into it.

Have fun crossy.gif

Peter.

Re: Black Beauty goes to the SPA for a make-over

Posted: Tue May 21, 2019 11:46 pm
by Easter
Like most of the bike, the turn indicator was broken, but have no fear it will be replaced with something that points in the right direction (sooner or later).

Today was power wash day and after giving myself and the bike components a thorough high pressure wash and de-grease, the parts were sorted in preparation for a trip to the powder coater. The engine will be painted in the next few days and draped with a flag from a local auto parts store until such time as the rest of the parts are ready for the assembly. All I need now is money. action1

Re: Black Beauty goes to the SPA for a make-over

Posted: Wed May 22, 2019 12:59 pm
by rcmatt007
Maybe the indicator was to let people on THAT SIDE know you are turning-LOL

Re: Black Beauty goes to the SPA for a make-over

Posted: Wed Jun 05, 2019 7:49 pm
by Easter
After a trip to the sand blaster, it turns out Black Beauty needs more than a trip to the spa. More like a trip to an orthopedic surgeon (one that knows how to weld). All of this was camouflaged with paint and putty. I am not much of a welder and my little wire welder tends to burn holes instead of produce a bead but I think I can fix this. The only place that is structurally significant is the cross member where the center stand mounts. A splice from another frame is welded over the weak areas and with a bit of grinding should do the job.

Re: Black Beauty goes to the SPA for a make-over

Posted: Thu Jun 06, 2019 8:04 am
by rcmatt007
that is nasty damage

Re: Black Beauty goes to the SPA for a make-over

Posted: Thu Jun 06, 2019 8:23 am
by robin1731
rcmatt007 wrote:that is nasty damage



Yeah, you say no structural damage but motor mounts rusted like that I wouldn't be too anxious to try to fix all that.

.

Re: Black Beauty goes to the SPA for a make-over

Posted: Sat Jun 08, 2019 4:50 pm
by Easter
Here is the next exciting group of photos. My welding is crude but thanks to a lot of grinding and a lot of JB Weld (original formula) I believe the joints will hold up. After welding a new skin on the lower mount of 14 ga steel, I filled the interior with a dozen or more 1 1/4 drywall screws (!) then filled the gaps with JB Weld. The top mount required four large pop rivets installed vertically. Then a filler panel of 14 ga was fitted into the gap and both sides filled with JB. Time will tell but this isn't an off road vehicle or a drag racer.

I once repaired the main pulley shaft of a mower deck for my garden tractor with JB weld and it was still holding years later when I sold the tractor. I don't have the same faith in the fast dry formula.

Re: Black Beauty goes to the SPA for a make-over

Posted: Sun Sep 22, 2019 9:37 pm
by Easter
I was away for most of the hot season here in TX so I have some catching up to do now than I am back. Black beauties new frame and engine paint is well cured (might say oven baked after 3 months in the closed garage) and ready for assembly. It is almost always a struggle when working alone to get the frame lined up on the engine but with the help of the lift and an overhead hoist I finally got all the bolts back in their respective holes. Now it is time to start emptying out the tubs full of parts I took off last spring and seeing what needs to be repaired or replaced.

Every time I use the hoist to lift the engine I have to figure out how to safely attach it to the lift hook. Every time I come up with something different. But here is a suggestion that worked really well and I hope I will be able to remember it next time. I used a spare fender brace from a GL1000 fender combined with a length of chain and a section of all-thread. Easy to attach and plenty solid.

Re: Black Beauty goes to the SPA for a make-over

Posted: Sat Oct 05, 2019 7:30 pm
by Easter
The bike is going back together in fits and starts. Had to wait for throttle cables before installing the carbs (much much easier when carbs are not bolted down) Unfortunately the first set were unusable as the inner cable was too long. Second set from Motion Pro arrived yesterday PM and went on without a hitch. An assortment of new nuts, bolts and washers also arrived yesterday. I cleaned up and cobbled together a set of instruments from two or three sets in the junk box. Light bulbs are all tested and the gauges appear to work. This is the first build in quite a while that I have used original instruments on but I am trying to keep it as close to stock as possible without making a big deal of it. That said I ran into a major problem today while attempting to rebuild the forks. After spending almost three hours attempting to extract the oil seal from one (the first one) of the lowers, I succeeded in breaking a chunk out of the upper edge. Bummer! Time for lunch and a nap.

Then I remembered that I had a more or less complete 83 front end. Not perfect but usable I think. That means I can use 83 wheels (just need to track down a rear wheel) and I don't know if I have calipers for the 83. So much for a restoration, but I much prefer the 83 style cast wheels to the early stamped style.

Re: Black Beauty goes to the SPA for a make-over

Posted: Sun Oct 06, 2019 8:08 am
by pidjones
I've learned to heat the end of my 1000 legs with a MAP torch until they smoke - ~400F by infared thermometer - then smack a regular automotive puller handle with a rubber mallet.

Re: Black Beauty goes to the SPA for a make-over

Posted: Mon Oct 07, 2019 5:24 pm
by Easter
Tried heat, eventually burning most of the seal. Lots of slide hammer action too.

Re: Black Beauty goes to the SPA for a make-over

Posted: Mon Oct 07, 2019 6:42 pm
by Easter
Here are some updated photos. Sorry if they are not easy to interpret. Lots of outside light and junk in the background.
Anyway, got the 83 forks cleaned and installed. Still lots to do. I have to track down a rear 83 wheel, front calipers and some brake mounting components, rear master cylinder is frozen and probably shot, front master cylinder is ugly and will be replaced along with brake lines. Need a headlight, upholstery for the seat and of course tires. Cam and timing belt covers need polishing and all the tupperware needs paint.

Other than that we are almost finished! lolol Oh, and I need the fork brace, anyone have one laying around?