79 Resto Mod

[chewy]

i've never tried it (intentionally) myself, but brake fluid should melt paint right off...

[Fred Camper]

This would be a good time to eliminate the front brake splitter. A double banjo bolt at the front master cylinder is all that is required, and a brake bleed becomes so much easier.

I like the idea of eliminating the splitter. Do you have a source or part number for the double banjo bolt and measurments for how long the hoses should be?

I used GTAutoSports, a fleabay shop. They did a good job and here are the details of my order for my 1977 Stock Wing;

1) Fitting 4 and 6 on each line
2) Each line 41.5 inch long fitting to fitting
3) Black hose and fittings
4) Fitting orientation 90 degrees
5) One Double Banjo 10x1.25

Of course now I am in the process of dropping my handlebars so these lines are coming off after only one season, as I need to order new shorter ones.

[Pokegama]

Beautiful project! I'm once again inspired by some really creative design color concepts. I have a similar project with a rebuild of my 77. My question is I'm looking to send out my frame and fenders to a powder coating shop. What's a thumb nail guesstimate of the costs for blasting and the powder coating?

For the full monty you should plan on around $500. That should cover the sandblasting and powder on most everything. I'm too impatient to sand and paint the frame myself and the powder just looks so good!
Good luck with your project!

[Pokegama]

This would be a good time to eliminate the front brake splitter. A double banjo bolt at the front master cylinder is all that is required, and a brake bleed becomes so much easier.

I like the idea of eliminating the splitter. Do you have a source or part number for the double banjo bolt and measurments for how long the hoses should be?

I used GTAutoSports, a fleabay shop. They did a good job and here are the details of my order for my 1977 Stock Wing;

1) Fitting 4 and 6 on each line
2) Each line 41.5 inch long fitting to fitting
3) Black hose and fittings
4) Fitting orientation 90 degrees
5) One Double Banjo 10x1.25

Of course now I am in the process of dropping my handlebars so these lines are coming off after only one season, as I need to order new shorter ones.

Thanks for the info Fred. What do you mean by fitting 4 and 6? Is that the size of the fittings? So if I read it right, both lines are the same length and were for the stock handlebars. I put Euro bars on so I should plan on going a little shorter. Correct?

[Fred Camper]

Yes, I have ordered Euro Bars and have not got them yet to measure the correct new length. I like to route them together from the master to below the center-line under the headlight, then split them one to each caliper. That way they are the same length. Fitting 4 and 6 are the style as shown on the GTAutoSports site, 4 is a upward bend of the banjo at 15 degrees while 6 is a flat banjo. Seems like the orientation was not perfect, I think 90 was about 15 degrees too much but it worked out just fine since the lines are 42 inches long they could twist that little bit.

[Pokegama]

Yes, I have ordered Euro Bars and have not got them yet to measure the correct new length. I like to route them together from the master to below the center-line under the headlight, then split them one to each caliper. That way they are the same length. Fitting 4 and 6 are the style as shown on the GTAutoSports site, 4 is a upward bend of the banjo at 15 degrees while 6 is a flat banjo. Seems like the orientation was not perfect, I think 90 was about 15 degrees too much but it worked out just fine since the lines are 42 inches long they could twist that little bit.

Thanks again Fred. I will give that a try.
I'm not sure I'm going to stay with the Euro bars. They look great but it feels like I'm stretching/reaching forward a little too much. I'm going to order some Daytona bars. They are a couple of inches higher but otherwise about the same. I'll report back how they feel.

[Fred Camper]

How tall are you Pokegama?, I bought the Euro based on Randall's input as he is 5' 11" about like me and he found them comfortable on RC-003. I have been too high in the wind for my liking with the stock 1977 bars and thought about going in between but did not want to do this twice. I did look twice at the Daytona bars.

[Pokegama]

How tall are you Pokegama?, I bought the Euro based on Randall's input as he is 5' 11" about like me and he found them comfortable on RC-003. I have been too high in the wind for my liking with the stock 1977 bars and thought about going in between but did not want to do this twice. I did look twice at the Daytona bars.

Fred, I am 5' 11" too. I have the Euro bars and the new Corbin seat on right now. It's not uncomfrotable but it just feels a little too forward for me. I just ordered a set of Bikemaster GP Touring bars to try out. They are only a couple of inches taller and about the same pullback. The Daytona bars have a smaller center and I was worried they might not fit. Hopefully they will show up in a few days. I will keep you posted!

[Fred Camper]

The rise is a compromise between city traffic where stock bars are very comfortable and highway where the stock bars put you up so far that the wind on your chest provides fatigue after an hour. Since my city trips are shorter, I will compromise comfort in the city to gain comfort on the highway. I do not ride the highway much but when I do it is for too long to ignore. What I do not know is how low I need to go to get highway relief.

Oh, and keep in mind that my comment above on 90 degree hose orientation is a function of my aftermarket front master cylinder. So a stock master may require a different orientation.

[Pokegama]

The rise is a compromise between city traffic where stock bars are very comfortable and highway where the stock bars put you up so far that the wind on your chest provides fatigue after an hour. Since my city trips are shorter, I will compromise comfort in the city to gain comfort on the highway. I do not ride the highway much but when I do it is for too long to ignore. What I do not know is how low I need to go to get highway relief.

Oh, and keep in mind that my comment above on 90 degree hose orientation is a function of my aftermarket front master cylinder. So a stock master may require a different orientation.

Fred, I agree about the bar height. The Euros feel like they drop me into a cafe racer kind of position. I like the look and like I said it's not uncomfortable but I think for me it would put too much strain on my back over a long ride.

Thanks for pointing out the aftermarket master. I looked in on your gallery and I can see what you're talking about. I have decided to go with Randakk's master with a double banjo bolt and two lines right to the calipers. I think the banjo bolt orientation is like the original equipment.

[Fred Camper]

Wish there was a good way to try new bars out before all the machining, cable and hose shortening and wiring effort. Just have to go with our gut on this one.

[Pokegama]

I received the GP Touring bars in today and threw them on the bike for a quick try. At first look they seemed just like the Euro bars but with more pull back. I do like them a little better than the Euros. I sit a little straighter without being up too far.


I gave striping the brake calipers a try, what a PITA. Mother Honda really put that caliper paint on thick. I did manage to get most of it off but the calipers will need a little sanding before painting.


I had the radiator cleaned, pressure tested and painted at a local shop. It looked so good I put it on the frame to see how it looked with the powdercoated parts.


More to come!

[robin1731]

You may want to have the brake parts powder coated also. The paint came off so hard because it was designed to be safe from brake fluid. Regular paint isn't too good with brake fluid.

The bike is coming along very nicely though.

[Fred Camper]

Fred, I agree about the bar height. The Euros feel like they drop me into a cafe racer kind of position. I like the look and like I said it's not uncomfortable but I think for me it would put too much strain on my back over a long ride.

Keep in mind that the lower and less pull back the bar has, then the higher the weight on the handlebar. Kind of counter intuitive, but less weight on your seat with lower handlebars. This is most noticeable in road biking where the neck can become uncomfortable for some but not too often do folks complain about the back. I am no doctor, and preference is a big deal. Looks like the touring bars will work out good.

Are you going to slot the bar for internal wires? I did mine today and it was not a big deal. There is a thread in the Tech section where I got advice then posted pictures.

Boy, the bike is sure looking sweet. Love the way it is coming together.

[Pokegama]

My original bars were not sloted and the controls all seem to be set up to have the wire outside the bars.