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| Renovating stock front forks https://vintagedirtbikeforums.alp-sys.com/viewtopic.php?f=21&t=1547 |
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| Author: | dogger315 [ Sun Aug 26, 2007 1:16 pm ] |
| Post subject: | Renovating stock front forks |
I am hip deep in "rescuing" a 1973 CR250. My current focus is on the front suspension. I have disassembled the forks and poured out the muddy water substituting for fork oil and ultrasonically cleaned all the components. I have found all new internals, a NOS right side case, had the uppers hard chromed and am refinishing the left side case to match the right. I know the OEM cases had a lacquer clear coat for protection, I want to put a clear coat powder coat for more protection since this bike will be ridden. Does anybody know if this is a good way to go (concerns about orange peel) or should I stick with the tried and true lacquer and run the foam fork protectors? dogger |
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| Author: | Dos Rios [ Sun Aug 26, 2007 4:54 pm ] |
| Post subject: | Re: Renovating stock front forks |
I'm also retoring a 74 CR250M. I beadblasted my lower forks, the forks are being rebuilt right now and I plan to paint them a light silver and cover with a clear coat. |
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| Author: | cbly [ Sat Dec 08, 2007 10:46 am ] |
| Post subject: | Re: Renovating stock front forks |
I sanded my lower fork cases with a 600 wet paper, sand grain should go in a direction around the case, they turned out really nice, planning on shooting the same clear that will be used on my tank when I get the tank finished. ANy local paint shop will be able to tell you the proper application for clear on aluminum. It takes some type of base preperation before applying the clearcoat, without it, the clear will peel. Good luck, Dog, attach some pics so we can see your progress. |
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| Author: | frohrs [ Sat Dec 08, 2007 2:41 pm ] |
| Post subject: | Re: Renovating stock front forks |
Think about going with some newer fork springs. I run Progressive springs in my 74 CR250 and they work nice! frohrs1 |
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| Author: | spedboat [ Sat Dec 08, 2007 8:17 pm ] |
| Post subject: | Re: Renovating stock front forks |
Hey Dogger, In my opinion, I wouldn't clear the forks if I was going to ride it. It's just going to chip and discolor. A good polisher can get you where you want to be. He can also re-polish when the forks start to look used. As far as powder coating the cases...YES! they will look great and wear alot longer than paint. Also, I wouldn't clear the tanks. Again, a good polisher can make the tank beautiful without clear. If the tank gets scratched with clear you have to strip it to make it good again. Good luck! Dan Troesken D.T.R. DAN TROESKEN RACING/RESTORATIONS 2007 VINTAGE IRON CHAMPIONSHIPS 250 EXPERT CHAMPION #1 1976 SUZUKI RM 250 1979 SUZUKI RM 125 1974 HONDA CR 125 1974 HONDA CR 250 1979 HONDA CR 125 1979 HONDA CR 250 #1 2006 YAMAHA YZ450F |
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| Author: | dogger315 [ Sat Dec 08, 2007 8:53 pm ] |
| Post subject: | Re: Renovating stock front forks |
Thanks for the tips guys. I ended up installing a set of NOS rebound springs and a set of Vintage Iron springs to replace the worn out OEM springs A & B. I used a lathe and flexible sanding block to smooth the scratches and pitting in the lower cases then hit them with several different kinds of buffing wheels and compound to yield a satin finish. I filled each leg with 165 cc of 15W fork fluid. The forks turned out pretty good and the action is like new only much stiffer due to the spring and fluid change. All that's left now is the ignition, seat and plastic. I will include some pics of my progress as soon as I figure out how to upload them to this site. dogger |
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| Author: | dogger315 [ Wed Jan 30, 2008 4:14 pm ] |
| Post subject: | Re: Renovating stock front forks |
I finally figured out how to upload photos so here are a couple of my project so far: [img]  [/img][img]  [/img]Since these shots were taken, I have mounted the restored expansion chamber, all the cables and the ignition. I will post some more pics when I get the plastic done. dogger |
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| Author: | spedboat [ Wed Jan 30, 2008 4:19 pm ] |
| Post subject: | Re: Renovating stock front forks |
The bike looks GREAT! It will be too nice to ride. |
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| Author: | cbly [ Wed Jan 30, 2008 5:04 pm ] |
| Post subject: | Re: Renovating stock front forks |
Sweet, Spedboat is right, its going to be to nice to ride. |
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| Author: | dogger315 [ Sat Feb 02, 2008 3:58 pm ] |
| Post subject: | Re: Renovating stock front forks |
Thanks for the "thumb up" guys. When I started this restoration, I had every intention of building a rider. But after all I have done to get it to this point, there is no way I would take it on a motocross track now. Unfortunately, the same will be true for the '79 CR250R I'll be doing next. I guess If I need a ride fix, I'll take one of my current bikes out. That way I won't be constantly worried about trashing a piece of motocross history, one that I have a huge investment in both time and money. Here is another picture I just took with everything but the tank, plastic, seat and coil. Almost there. dogger [img]  [/img]
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| Author: | ktm450exc [ Sat Feb 02, 2008 7:17 pm ] |
| Post subject: | Re: Renovating stock front forks |
purrrty! Did you rebuild the motor or send her out? my vote is ride it! |
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| Author: | Dos Rios [ Sun Feb 03, 2008 9:26 am ] |
| Post subject: | Re: Renovating stock front forks |
dogger, i know the feeling. It went too far on my 74 Elsinore 250 restoration as well. I won't even put gas in the tank. It sure looks great sitting in my restoration shop! |
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| Author: | ktm450exc [ Sun Feb 03, 2008 11:49 am ] |
| Post subject: | Re: Renovating stock front forks |
I've done two frame up total rebuild/restorations one on a 78-79 and a 73-74. On the 78-79 I was of the mind set that I wanted it to look brand new... I did it and it turned out very good. On the 73-74 I just tried to repaint and shine up the parts that needed it, going for a full mechanical restoration, clean and correct but not showroom knowing if I wanted to do the showroom deal I always could .... I think I like the restored but used look.. Of course I'm not displaying mine or anything.. |
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| Author: | dogger315 [ Sun Feb 03, 2008 1:02 pm ] |
| Post subject: | Re: Renovating stock front forks |
Dos Rios, I remember when you were restoring yours and the pics you posted when it was done - sweet. You have to admit though, it s*cks not feeling comfortable riding a bike you poured so much into because of the scarcity of parts. Ktm450exc, I did rebuild my engine. This was one of those lessons learned about starting a project with as good a bike as you can get. My first clue things were bad was when I opened the clutch cover and found two whole tines were missing from the clutch basket. When I split the cases, the return spring pin was missing and there was a big hole where it used to be mounted. There were also numerous stiffening ribs and castings that were broken off and missing as well. The oil drain casting had been butchered and a pipe bolt had been forced into the drain hole. At this point I considered this project more of a rescue than a restoration and I was determined to restore the dignity to this poor bike so the other bikes would stop laughing at it. I salvaged a few restorable parts and junked the rest. I found a nice set of center cases, an NOS crank and rod, low time main and secondary shafts, NOS tranny gears, shift drum, shifter arm shaft, and shifter arms. All the bottom end bearings and seals were replaced. All thrust washers, circlips and springs were replaced. For the clutch, I found an NOS outer inner and pressure plate and loaded it with NOS plates and springs to finish the bottom end. The cylinder bore was crap so I had a liner installed by Racer's Toy Store and fitted a new piston and rings topped off with an NOS head. Every nut, bolt, stud and washer is NOS. Like everything else on this project, I tried to the max to recreate the bike just as it was the day it rolled off the dealer's floor. Originally, I had planned to install a PVL ignition (I even purchased one) but later decided to stick with OEM and managed to find an NOS stator, coil and rotor, the only piece I'm missing is an original wiring harness (I'm still looking though). I spent many hours restoring the clutch and ignition covers which were covered with road rash, rock chips and scratches. As you know, Magnesium is a finicky metal to work with and it can quite lterally blow up in your face if your not careful. I used a TIG welder and magnesium rod to fill all the gouges then wet sanded the surfaces smooth followed by powder coat primer and satin black. I know this a lengthy dissertation about the engine rebuild but it only scratches the surface. I have similar stories about every component on this bike. One thing is for sure, I have learned a ton and really look forward to starting on my '79. I think I am totally hooked on vintage bikes and vintage restoration. Below is a picture of my engine just prior to "buttoning up" the cases. dogger [img]  [/img]
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| Author: | ktm450exc [ Mon Feb 04, 2008 1:33 pm ] |
| Post subject: | Re: Renovating stock front forks |
Yea mine had a few issues but not as many as yours.. My motor was in pretty good shape so all I needed to do was rebuild it, have a rod kit installed on the crank and put it back together.. I had also made a pact with myself that I wasn't going to screw around with the original points/ignition, if it didn't give me spark I would trash it and go PVL. Luckly, I got it all together checked for spark, got it put the plug wire on and it fired after the 3rd kick  Is that a billet crank?? |
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