My 8100 mile 76 LTD, the Olde Wing

[DET17]

This post documents my efforts to save my RH exhaust header, which had been dropped severely somewhere in the past.
I scouted for a rust free replacement, but could not find one. Apparently the headers from 75-77 which mate with the horseshoe muffler are unique to that system; I did purchase a 78-79 header and it clearly won't mate up with the original muffler.

Here is what the damaged RH header looked like, after I sanded off all the rust:



I decided to get her down to bare steel and then "build it up" with my Millermatic 175 MIG machine. It took about 3 passes of laying welds and then grinding them with my Makita side grinder. Here are the progress pics as I replaced the ground away steel:






With the majority of the steel replaced, I took the pair of 76 headers to my local powder & ceramic coating company. Considering the half dozen color options, I decided on the Titanium color. Here are the coated headers and the original muffler:



Closeup of the LH header, along with the Honda copper "dead soft" gaskets which install up into the exhaust ports. You have to work a bit to pry out the previous set of gaskets..... it isn't obvious that the copper gasket is there, but they certainly are. There is a small notch at one point for each exhaust port, to allow a very sharp small screwdriver to gain leverage. I found the exhaust nut spec in my manual listed from 11-14 lb. ft of torque.



So upon fitting the headers and muffler, I realized immediately that the stock muffler (black paint & light rust) wasn't going to cut it..... especially in contrast to the sweet new headers. Back to the Powder company in order to get that horseshoe exhaust ceramic coated black. Final pic, was squeaking the muffler inlet pipes past the center stand (a very tight fit, but it does fit). I'll share pics of the complete exhaust once I have my ceramic coated muffler back inhand.

[GalDemSuga]

This is coming along great

[ritalz]

Nice work.

[DET17]

Long time, no update! I've been consumed with a retirement construction build in east TN, so I'll take this opportunity to bring things current.

Last update, I sent my OE '76 "horseshoe" exhaust muffler to my local coater for ceramic treatment. Figured I better try and preserve what I've got, as these early versions are NLA. I asked for a satin black to attempt to replicate the original paint. Here is a close up of how it came out:



Next it was time to install the muffler for the 2nd time (with tire & wheel on the bike). Well I immediately learned from another burn that thou shalt not install the headers FIRST, muffler SECOND. It is impossible to makeup the gasketed sleeve joint between the two. Plenty of mistakes possible on the path to resurrection for the LTD.

Back OFF with the headers, buy yet another set of dead soft copper gaskets for the exhaust ports in the heads. FIRST, assemble the headers into the muffler (junction sleeve clamps loose but assembled), then SECOND start the headers on the exhaust studs. THIRDLY hang the horseshoe muffler from the frame mounts out back and bring everything up to proper elevation. LAST, torque the dead soft gaskets to make the header seal against heads as well as the gasketed sleeve joints. LOTS of fun rolling around the old bike on concrete, thankfully my creeper eased the pain. I think it looks pretty good, what do y'all think?





Used my 500 lb-inch vintage Craftsman needle type wrench to dial the torque in. No more clicker wrench usage on this machine.

Another loose end were the engine top side water pipes. Mine had been subjected to channel lock/pipe wrench jaws and had some bad spots. I bought a couple replacement used pipes off eBay, then took the best of the lot to the power coater. I also had the T-stat and temp fan controller housing PC'd to match, so everything was as close to HONDA color as I could eye ball. 100% new gaskets, cleaned threads & mating surfaces, installed an NOS T-stat with the bleed hole @ 12 o'clock to get the air out. Glad to have the area cleaned up and restored as well! Here is how the cooling pipe assembly looks:




That's where she stands right now. Up next, hopefully farming out the OE LTD carb assemblies for a complete overhaul by "the right guy", wherever he is. I just don't have the time with my other commitments to learn how to rebuild these carbs, so sending them off to the experienced hand is what I'm planning to do.

[DET17]

Just a quick thread bump..... lots of delays in finding time to work on the 76 LTD. Add to that, my quadruple heart bypass on 4/18/24. I'm fine, stronger every day. Back to work with construction duty in east TN probably until Q4 of '24.

In the period between I plan to send my carbs out for overhaul by the NGW resident expert.

I'll post up a pic of the "as found" set of LTD carbs, and later what they look like overhauled. Once carbs & induction are complete, I must finish the cooling system and then rebuild the front forks as well as front brakes/master. With those milestones, we should be dangerously close to being able to FIRE the engine on my long dormant 76. Instrument cluster needs some love, and I understand the supply chain to JAPAN still works to source many of those needed parts.

Onward!