New LC project.... Restoration... I know, I know...

Got a customizing or restoration project? Discuss it here

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JonW
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Re: New LC project.... Restoration... I know, I know...

#301 Post by JonW » Tue Jan 23, 2018 7:30 pm

In Sydney we only get a few mid to high 40's days every year, but the problem is that most sheds and garages have no AC and fans (no matter how big) just dont cut it sadly, so yeah progress slows down. Our winter is like UK summer, much more gets done then lol.
80 XT500 Supermoto!
81 RD350LC Resto
82 RD421LC Hybrid
82 RD350LC decapitation project
82 RD250LC JDM '251LC' YPVS
83 RZ350 Resto
84 RZ500 Resto
85 RZ350 F1 Resto
86 RZ350 F2 Resto
86 RZ350 F2 Hybrid

Like Watches? www.PloProf.com & www.DeskDivers.com

hondaror
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Location: Alberta, Canada

Re: New LC project.... Restoration... I know, I know...

#302 Post by hondaror » Tue Jan 23, 2018 8:49 pm

I bet.
I'm just finishing up 12 weeks of school. This is normally our productive time. Summer here is for riding at all costs. Lol
Rory
2 1984 RZ350s
1985 RZ350
9 1986-1990 RZ350s
2000 ST2
2005 749
2005 749 with 999 engine

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JonW
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Re: New LC project.... Restoration... I know, I know...

#303 Post by JonW » Tue Jan 23, 2018 9:06 pm

yes I can imagine, 2 solid weeks of pure heaven :D
80 XT500 Supermoto!
81 RD350LC Resto
82 RD421LC Hybrid
82 RD350LC decapitation project
82 RD250LC JDM '251LC' YPVS
83 RZ350 Resto
84 RZ500 Resto
85 RZ350 F1 Resto
86 RZ350 F2 Resto
86 RZ350 F2 Hybrid

Like Watches? www.PloProf.com & www.DeskDivers.com

hondaror
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Joined: Mon Mar 03, 2014 8:44 pm
Location: Alberta, Canada

Re: New LC project.... Restoration... I know, I know...

#304 Post by hondaror » Tue Jan 23, 2018 9:47 pm

We're a little better than that. About 7 months.
Rory
2 1984 RZ350s
1985 RZ350
9 1986-1990 RZ350s
2000 ST2
2005 749
2005 749 with 999 engine

hondaror
Posts: 2828
Joined: Mon Mar 03, 2014 8:44 pm
Location: Alberta, Canada

Re: New LC project.... Restoration... I know, I know...

#305 Post by hondaror » Tue Jan 23, 2018 9:47 pm

We're a little better than that. About 7 months.
Rory
2 1984 RZ350s
1985 RZ350
9 1986-1990 RZ350s
2000 ST2
2005 749
2005 749 with 999 engine

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JonW
Posts: 10599
Joined: Sat Oct 10, 2009 4:33 am
Location: Sydney
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Re: New LC project.... Restoration... I know, I know...

#306 Post by JonW » Tue Jan 23, 2018 10:04 pm

heehee :)
80 XT500 Supermoto!
81 RD350LC Resto
82 RD421LC Hybrid
82 RD350LC decapitation project
82 RD250LC JDM '251LC' YPVS
83 RZ350 Resto
84 RZ500 Resto
85 RZ350 F1 Resto
86 RZ350 F2 Resto
86 RZ350 F2 Hybrid

Like Watches? www.PloProf.com & www.DeskDivers.com

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JonW
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Re: New LC project.... Restoration... I know, I know...

#307 Post by JonW » Fri Mar 02, 2018 2:24 am

Ok, there has been no progress on this for two reasons:

1, The cylinder head was leaking coolant. OEM gasket and OEM torque settings... back in the day I used neither, (re)used whatever cheap gasket i could find and did stuff by feel. Never had and RD/RZ leak. Ever. hmm... Tightened the head bolts to about 1.5x the setting and it's much better, very small weep only... but its still not quite right. Plan now is that I will run it a few times and see if it seats better after another torque down, otherwise its got to come off. sigh.

2. For ages as I just couldn't get the pressure test to work. Initially i bought Yambits' inlet rubbers and they couldnt hold the crossover in them, the part where the clip goes is just useless. Total junk. They also leaked where they bowed when tightening them up and eventually I heard them snap internally when trying to get them tight enough to seal. Ooops. I reckon they have a plastic frame in the them, not alloy like the OEMs. Like i said, j u n k... I quickly bought two new OEMs off norbo but I didn't give him my address so he didnt send them rightaway, only when i mentioned they hadnt arrived after 6 weeks did he tell me he didn't have my address, er ok it was in the same PM from a previous order a few weeks earlier, so I assumed... Now anyone who knows me will know that I would totally believe thats all on me, no one else. I should know better than to assume and don't get me wrong I believe Norbo was right to wait as sending them to the wrong address could easily be worse than wrong, but it would have been good to be prompted.
Anyway, with those OEM inlets (really nice compared to the Yambits (PGM?) versions) finally here I was back on the pressure test and it was worse than ever. WTF?! I just couldn't get anything to pressure up at all. I was pissed off enough to just work on other stuff and leave this 99% done bike in a corner to think about what it had done. Today I had LB visit and we had a good look and with two people and a larger pump we found that you could hear the air escaping, turns out the pressure test kit exhaust bungs had got soft with the summer heat and were now totally loose. Something to bear in mind with 3D printed parts I reckon. My garage hits way over 50Deg on warm days and plastic doesn't always like that, and bear in mind 3D printing plastic has already been heated once and i'm sure its a low temp plastic to make the printer perform better. So, really I have to say that maybe things 3D printed are not ideal in my environment. I'll end up making some out of thick plate steel I guess. Super annoying to say the least tho, but at least I had located the issue and had a plan. After LB headed home I worked out a better way to seal the cylinders and lo-n-behold I had pressure. Cranked it up to 5psi and walked away.... and it lost 0.25psi in 30mins. I'll take that.

So, next job is pipes and carbs to go on and kick it over... Ahh but the carbs need their idle screws plated though, that wont happen until the end of the month. Damn...
80 XT500 Supermoto!
81 RD350LC Resto
82 RD421LC Hybrid
82 RD350LC decapitation project
82 RD250LC JDM '251LC' YPVS
83 RZ350 Resto
84 RZ500 Resto
85 RZ350 F1 Resto
86 RZ350 F2 Resto
86 RZ350 F2 Hybrid

Like Watches? www.PloProf.com & www.DeskDivers.com

hondaror
Posts: 2828
Joined: Mon Mar 03, 2014 8:44 pm
Location: Alberta, Canada

Re: New LC project.... Restoration... I know, I know...

#308 Post by hondaror » Fri Mar 02, 2018 3:47 am

Hey, steps forward, are steps forward. Good work guys!
Rory
2 1984 RZ350s
1985 RZ350
9 1986-1990 RZ350s
2000 ST2
2005 749
2005 749 with 999 engine

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JonW
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Joined: Sat Oct 10, 2009 4:33 am
Location: Sydney
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Re: New LC project.... Restoration... I know, I know...

#309 Post by JonW » Fri Mar 02, 2018 7:07 pm

Thanks Rory. Finally this one moves forwards.

Next big job is to have the bodywork painted... my poor wallet. Painters in Sydney must have had 3 nasty ex wives, live in mansions, drive Ferraris that are out of warranty, send their kids to private schools and have a massive coke habit. If not, I really dont know what they do with all the money they charge for their work. hmm...
80 XT500 Supermoto!
81 RD350LC Resto
82 RD421LC Hybrid
82 RD350LC decapitation project
82 RD250LC JDM '251LC' YPVS
83 RZ350 Resto
84 RZ500 Resto
85 RZ350 F1 Resto
86 RZ350 F2 Resto
86 RZ350 F2 Hybrid

Like Watches? www.PloProf.com & www.DeskDivers.com

critchlg
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Joined: Fri Feb 06, 2015 11:10 pm

Re: New LC project.... Restoration... I know, I know...

#310 Post by critchlg » Fri Mar 02, 2018 7:14 pm

I had the same with my pressure test kit. First time I used it the exhaust blanking plates wouldn't seal. Torqued them up, changed the rubber seals, still no good. Had a mate machine me up some copies in aluminium, slipped the rubber back on and hey presto. Job done. The 3D printing plastic is too flexible to last.

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JonW
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Re: New LC project.... Restoration... I know, I know...

#311 Post by JonW » Fri Mar 02, 2018 7:27 pm

Interesting you had the same problem Gavin as I've not read of any problem on other forums so assumed it was just me. In fact I really struggled with the first kit I had with the inlets being too small and Dan kindly sent me another kit as he'd found some early kits had that issue. When looking for a solution yesterday I pulled out the old kit in case any parts would be useful (which they were) and found that where I had done the exhaust plates up tight they had obviously cracked but must have looked ok when i put them away or i'd have chucked them out. When i pulled them out of the bag one of them is almost in half. again the cost of this low temp plastic in my hot garage, plus the stresses involved in getting a good seal. I will have a look at my mates workshop for some steel and plasma something in this shape i think. For my 421 I bought pool bungs, but they were way over $50 the pair for simple bungs (typical pool shop prices) and of course they dont fit in the LC cyls due to the banshee design of the Athenas and they are larger of course. For the 34mm carb inlets on that bike I made up some fittings with plumbing pipe end caps and some old screw in schrader valves, worked a treat. Anyway, I need to make new plates, Ive too many engines to do and need these to be reliable.
80 XT500 Supermoto!
81 RD350LC Resto
82 RD421LC Hybrid
82 RD350LC decapitation project
82 RD250LC JDM '251LC' YPVS
83 RZ350 Resto
84 RZ500 Resto
85 RZ350 F1 Resto
86 RZ350 F2 Resto
86 RZ350 F2 Hybrid

Like Watches? www.PloProf.com & www.DeskDivers.com

critchlg
Posts: 16
Joined: Fri Feb 06, 2015 11:10 pm

Re: New LC project.... Restoration... I know, I know...

#312 Post by critchlg » Fri Mar 02, 2018 7:33 pm

Use the plastic one as a template over 10mm aluminium bar. 5 minutes on the linisher and two drill holes. Surprised no one produces these instead of the 3D printed ones tbh

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JonW
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Re: New LC project.... Restoration... I know, I know...

#313 Post by JonW » Fri Mar 02, 2018 7:34 pm

Alloy is easier to work with of course but I think i stand a better chance of finding steel in the scraps pile. :)
80 XT500 Supermoto!
81 RD350LC Resto
82 RD421LC Hybrid
82 RD350LC decapitation project
82 RD250LC JDM '251LC' YPVS
83 RZ350 Resto
84 RZ500 Resto
85 RZ350 F1 Resto
86 RZ350 F2 Resto
86 RZ350 F2 Hybrid

Like Watches? www.PloProf.com & www.DeskDivers.com

User avatar
JonW
Posts: 10599
Joined: Sat Oct 10, 2009 4:33 am
Location: Sydney
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Re: New LC project.... Restoration... I know, I know...

#314 Post by JonW » Mon Mar 05, 2018 3:28 am

When removing the bungs in the inlets one of the tangs was cracked all the way across and 90% off. It seems that these are hollow inside. Nothing had pressed against these since they were fitted and at that point they were pretty much new, defo unused. So im sad to say 3D printed plastic parts are not conducive to 50+ garage temps. :(

Anyway, carbs now fitted. Im waiting on the idle screws and the top adjusters to be plated but the oil lines and choke are fitted so these are almost ready to go.

I also fitted the exhausts with extra 'pressure' rings made of wire coat hanger. I think theyre a little thin if im honest as they snag in the out collars as they have a gap around the pipe. I nee to locate some thicker wire.

But... with carbs and pipes on this is looking more and more finished every day...
80 XT500 Supermoto!
81 RD350LC Resto
82 RD421LC Hybrid
82 RD350LC decapitation project
82 RD250LC JDM '251LC' YPVS
83 RZ350 Resto
84 RZ500 Resto
85 RZ350 F1 Resto
86 RZ350 F2 Resto
86 RZ350 F2 Hybrid

Like Watches? www.PloProf.com & www.DeskDivers.com

User avatar
JonW
Posts: 10599
Joined: Sat Oct 10, 2009 4:33 am
Location: Sydney
Contact:

Re: New LC project.... Restoration... I know, I know...

#315 Post by JonW » Sun Mar 11, 2018 11:08 pm

While I wait for my plating to come back as it has the carb tops and idle screws in this batch, I've test fitted the bodywork and this lump of parts is looking more and more like a real bike.

In the pic the seat foam is just that, no base. The base has now been partnered with a brand new aftermarket foam from the UK and will be covered by a NOS OEM seat cover. Interestingly the base came up like new when cleaned in my mates Ozyjuice parts washer and I've since also re-zinc'd the seat latch parts, the captive bolt plates and the original nuts and washers of course; everything new or restored :)

Image

Ive also had some fun and games with the flasher unit this week. I wanted an OEM flasher unit to keep this bike OEM and Evan sent me a couple (thanks mate!). These landed but didn't work... hmm... now with the one Rob in Aus sent me I had 3 that didnt work. damn! I figured quickly that the bulbs in the units i had were 21W and not 27W, I went through my stash of old indicators and found only two had 27s... wow, how quickly our bikes lost the Nippon Denso units I guess*. I fitted those bulbs and... still nothing... just a tiny tick when switched on and then another when switched off. Swapping the black and yellow wires made these units freak out with manic ticking. So, from that I knew they worked but something was wrong in the connections, I just didnt know what. Asked on Norbos forum and the lads came to the rescue and using a pic supplied by Nigel I sussed it right away, someone had swapped the terminals in the connector to run a car or some other aftermarket unit.

How the connector is wired OEM can be found in OEB's pic here:
http://rdlccrazy.proboards.com/thread/4 ... asher-unit" onclick="window.open(this.href);return false;

I swapped back my connections and these units now work like a charm. Phew! Gotta love the forums, I certainly couldnt do this without the help from everyone on them, it took 2 forumers to send me units and 3-4 guys to help with the wiring... I know a fair bit about these bikes and about automotive wiring but, we cant all know everything! :smt023

* - I've since found that if you run the ND unit with 21w bulbs it wont tick at all. Even with 23w's it wont work. It will only run with the 27w units and theyre not always easy to find, online seems the only way.
Last edited by JonW on Mon Mar 12, 2018 8:09 am, edited 6 times in total.
80 XT500 Supermoto!
81 RD350LC Resto
82 RD421LC Hybrid
82 RD350LC decapitation project
82 RD250LC JDM '251LC' YPVS
83 RZ350 Resto
84 RZ500 Resto
85 RZ350 F1 Resto
86 RZ350 F2 Resto
86 RZ350 F2 Hybrid

Like Watches? www.PloProf.com & www.DeskDivers.com

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