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Blackbird Clean Up

Posted 21 March 2017 - 02:37 PM (#1) User is offline   Fozzie Jr 

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Hello everyone, I haven't been on here for a while but I'm just going to jump right back into it.

I have a Blackbird now, which used to be my Dad's. It was sat near the sea in a garage for a couple of years, which more or less ate its insides alive.

I didn't take many pictures as often I zone out and focus on what I'm doing but here's what I got.

First stop was the centre stand. The old vs the new. The new I gave a light dusting of stone chip after cleaning and clearing the rust. I gave it a few more and it went on the bike looking like a new item.
http://i943.photobucket.com/albums/ad275/Chris-Fozzie/IMG_6619.jpg

http://i943.photobucket.com/albums/ad275/Chris-Fozzie/IMG_6600.jpg


With that out of the way I looked to getting the fairing off. I'll save the picture I took until the end but it was a mess. I found.

1. Heavy amounts of rust to brackets which would need cleaning and a coat of stone chip.
2. An oil filter that had almost returned to nature it was so rotten.
3. Oil cooler lines that were leaking and rotten.
4. Rust was beginning to attack the downpipes.
5. The engine covers were buggered.
6. The radiator was heavily rusted and when I tried to take the bottom mount off, my thumb when *clean* through the cores and nearly out the other side.
7. The bolts in the engine cases were rotten and it looked very untidy.

So I stripped it all down and cleaned it. Fitting a new oil filter.
http://i943.photobucket.com/albums/ad275/Chris-Fozzie/IMG_6868.jpg


The oil lines were a piece of work. My dad told me not to touch them and repair the old lines, the internet told me I'd face certain doom, even I thought I better not try. However my head translates this as "OOOH A CHALLENGE". While I don't regret it, these 4 bolts on the bottom of the engine took me 4 hours to remove. The first came out with a good smack with a chisel and hammer loosening it. The second sheared but I was able to get enough purchase on it with the chisel and free it off. The third needed left handed cobalt bits to get out with a heavy attack with a blow torch. And the forth not only snapped but took part of the engine block with it and required me to rebuild it using a steel epoxy, which I'd been told by boat enthusiasts had been used to fix marine exhausts and last 15+ years.
http://i943.photobucket.com/albums/ad275/Chris-Fozzie/IMG_6763.jpg?t=1490019296

http://i943.photobucket.com/albums/ad275/Chris-Fozzie/IMG_6766.jpg?t=1490019388

Cured it supposedly is as strong as steel... Which is good as the engine is aluminium.
http://i943.photobucket.com/albums/ad275/Chris-Fozzie/IMG_6844.jpg?t=1490019440


Buggered engine cover
http://i943.photobucket.com/albums/ad275/Chris-Fozzie/IMG_6689.jpg


And the refresh
http://i943.photobucket.com/albums/ad275/Chris-Fozzie/IMG_6690.jpg

http://i943.photobucket.com/albums/ad275/Chris-Fozzie/IMG_6793.jpg


http://i943.photobucket.com/albums/ad275/Chris-Fozzie/IMG_6836.jpg


Then to the radiator. My Dad very kindly sourced one from Jaws motorcycles, surprisingly cheap and even more surprising was how good the quality was!

Old radiator
http://i943.photobucket.com/albums/ad275/Chris-Fozzie/IMG_6834.jpg


Vs the new
http://i943.photobucket.com/albums/ad275/Chris-Fozzie/IMG_6896.jpg


And finally the big before and after pic. The after pic shows the engine casings done with fresh bolts, HEL braided stainless oil lines which shout outlive the bike. Fresh exhaust clean and new copper gaskets. A new radiator.

Before
http://i943.photobucket.com/albums/ad275/Chris-Fozzie/IMG_6601.jpg


And after
http://i943.photobucket.com/albums/ad275/Chris-Fozzie/IMG_6878.jpg

The murky finish on the exhaust is dried on WD40 as I gave it a very deep scrub with wire wool.

My plans for this year which will have updates on this thread.

1. Wheel and steering bearings
2. De-link the brakes (I'm growing to hate the combined system)
3. Reverse glow clock backings
4. Repaint the right hand panel which was subject to a botch job
5. Powdercoat the wheels a deep dark blue
6. Replace the clutch line and levers
7. LED indicators and running lights so I'm not using the HID during the day.
8. Repaint and rebuild the forks with progressive springs and set up accordingly.
9. Fresh bolts throughout.
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Posted 21 March 2017 - 04:32 PM (#2) User is offline   Fozzie 

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....just thinking about changing the oil cooler pipes makes me shudder... those bolts turn into twigs after a few years on the bike - but those replacement Hel lines are brilliant... nice job :thumbsu:

Still amazes me the amount of corrosion on it after 18 months in a garage with sea air.... as I'd only replaced the oil filter about 6 months before it got parked up :shok: .... note to myself, always get an annual ACF50 treatment for bikes used in a coastal area. :good:
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Posted 21 March 2017 - 06:19 PM (#3) User is offline   b_hawk111 

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Looks like another good rebuild to read about!

Keep up the good work :)
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Posted 21 March 2017 - 08:36 PM (#4) User is offline   Fozzie Jr 

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The oil cooler bolts rank in the top 5 most difficult jobs I've had. For context, in that list is a situation where I had to drop an engine, flush out pits of blown up piston and cylinder from the bottom end, fit a new top end, and get the engine back in and running in 6 hours as with travel it was 8 hours and I had a dog to look after who couldn't be left longer than that.
The state of corrosion here suggests it was at the hard end of a bad spectrum so I wouldn't fear doing it on blackbirds with less corrosion. But I would suggest the average home mechanic ask someone whose done it on the methodology as a socket would have sheared all 4.

Hawk I have another thread in mind that will need your help. I picked up a Bandit MK1 for free (fire damaged).
The engine has been fully and professionally rebuilt so I'm nearing the point I can start the main build. But I'm going to need help with routing the loom, and hoses as I have only ever known this bike as a machine I put out the fire on, then immediately tore it down before the owner Ricky said "Do you want it? I can't fix this" http://www.bikerforum.co.uk/public/style_emoticons/default/yahoo.gif

And Dad, the garage has been tidied and a second work bench made, so when you're ready to send your Bird over you know where I am. http://www.bikerforum.co.uk/public/style_emoticons/default/rock.gif
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Posted 21 March 2017 - 09:14 PM (#5) User is offline   b_hawk111 

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View PostFozzie Jr, on 21 March 2017 - 08:36 PM, said:

The oil cooler bolts rank in the top 5 most difficult jobs I've had. For context, in that list is a situation where I had to drop an engine, flush out pits of blown up piston and cylinder from the bottom end, fit a new top end, and get the engine back in and running in 6 hours as with travel it was 8 hours and I had a dog to look after who couldn't be left longer than that.
The state of corrosion here suggests it was at the hard end of a bad spectrum so I wouldn't fear doing it on blackbirds with less corrosion. But I would suggest the average home mechanic ask someone whose done it on the methodology as a socket would have sheared all 4.

Hawk I have another thread in mind that will need your help. I picked up a Bandit MK1 for free (fire damaged).
The engine has been fully and professionally rebuilt so I'm nearing the point I can start the main build. But I'm going to need help with routing the loom, and hoses as I have only ever known this bike as a machine I put out the fire on, then immediately tore it down before the owner Ricky said "Do you want it? I can't fix this" http://www.bikerforum.co.uk/public/style_emoticons/default/yahoo.gif

And Dad, the garage has been tidied and a second work bench made, so when you're ready to send your Bird over you know where I am. http://www.bikerforum.co.uk/public/style_emoticons/default/rock.gif


Yep no worries start a thread for it and I will help as much as I can! My mk2 is very slightly different but I believe it all runs in more or less the same way!
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Posted 22 March 2017 - 10:06 AM (#6) User is offline   patyogi 

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You would be very welcome in the 'Honda XX Blackbird ' Forum. They love refurbs.
My Bird has been cosseted most of it's life, so I just service and polish her. Best bike ever!

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Posted 31 March 2017 - 07:27 PM (#7) User is offline   bikingviking 

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Anyone else feel completely out of their depth on this forum nowadays?

Impressive work, Jr.
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Posted 01 April 2017 - 01:32 PM (#8) User is offline   Nevstah 

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While I've got plenty of tools and ability, time is the biggest thing, plus i don't have some of the more specialist tools
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Posted 05 April 2017 - 12:29 PM (#9) User is offline   Fozzie Jr 

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View Postbikingviking, on 31 March 2017 - 07:27 PM, said:

Anyone else feel completely out of their depth on this forum nowadays?

Impressive work, Jr.


Thanks. This stuff wasn't too hardcore in my view, just time consuming. The top end refresh I'll be doing at the end of this year will be where I earn my stripes. I'm planning to have the head skimmed, and the valves cleaned up and reground. I have a friend who can help me with the machining side of things for free providing I take him to Nandos. Fresh stem seals as I'm trying to avoid the blue smoke on start up that signals they are getting on a bit.


View PostNevstah, on 01 April 2017 - 01:32 PM, said:

While I've got plenty of tools and ability, time is the biggest thing, plus i don't have some of the more specialist tools


Make time! It sounds easy to say but I work an hour away from home, I go to the gym 4-5 times a week so most of my evenings are spent as a result. I literally cram in 30-45 minutes where I can. Or 2 hours if the stars line up and give me a shot.
Keep a diary book (I use a spiderman notepad) to keep track of what you do, the size of the bolts and so on. Then when you rebuild you just follow the reverse order of what you've written. Makes reassembly much faster.
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