1981 XL185S Pooched Parts Bike

[XLsior]

Originally Posted by TominMO

I like your paint stand too.

Old ironing tables are very useful especially if you never do any clothes ironing.

[XLsior]

with 2 sets of 81 rims was hoping for better...

but they are all rough...

the 2 rims without tires came from the original pooched 81...
they looked decent from the outside but when the rubber came off it was evident they were roached....hubs/bearings were decent though. spokes ok.

The recent 81 wheels looked rough on the outside...few loose spokes, more rust etc...

But the tires hold air pressure...so I deflated them to see behind the side wall...and though its a bit crusty, there is decent rim tape...so I squirted some lanolin rust inhibitor around and pumped them back up...

the rear wheel is the roughest externally and the bearing was not rolling...

But the other rear rim was cactus...

I did not want to bother with swapping/replacing bearings...

So I managed to degreaser blast and pick out the grunge in the bad bearing to where they rolled albeit a bit ratchety, packed with fresh grease and called it good.

These are not road going wheels just for beating around the yard. cant do much about the couple of loose spokes (nuts are seized)

just going to clean them up as best as I can with a wire wheel and hit them with spray paint...

The other better condition hubs will go to a new rim and spoke replacement job when my 92 road xl185 needs new rubber...

[XLsior]

Most of the projects are collecting dust at the moment while other more important things are filling up my time now.


I have not forgotten about them.


The 81 is still a lounge ornament waiting for me to decide on making a battery holder before bolting more parts to the frame...


On another matter, I've been tweaking the Nibbi PE28FL constantly now on the main bike, that I started to looking at the PZ30B again as I recall it was pretty good when I removed the pumper assembly and ran it on a stock piston and cylinder CG250.


I found a knob kit for the PZ30 which replaces the PITA A/F screw and Idle screw.


I'd say the A/F knob is just enough to make adjustments with the carb installed.


The Idle knob will not work with a pumper assembly, but should fine on a non pumper PZ30.

[cheesy]

Originally Posted by XLsior

Most of the projects are collecting dust at the moment while other more important things are filling up my time now.


I have not forgotten about them.

Boy, do I know that feeling.

[XLsior]

Had some time to spend on the 81...


No battery bracket yet, but I was going to need a seat at some point and had the bits about.


Just one of those 'cafe racer' style seats with a bit of heatgun treatment and some 6mm button hex head bolts and mudflap washers.


Better than no seat...

[XLsior]

A bit more progress on the 81 naked XL185


With a section of scrap bar stock I added a support cross bar to give something for a battery/regulator/solenoid to mount to.


Predrilled some 5.5mm holes and thread tapped to M6.


Don't make the mistake of welding with bare bolt threads ( I had to cut them down and throw them out)


bit of flap disk and some dremel made the welds less shit and I wringed the last splurt of paint out of the can to cover it up and stop rust...


Next will be some cardboard aided design (CAD) for the actual Battery box.

[cheesy]

snort

Cardboard
Aided
Design



That's a hell of a lot classier than my "Gimme dat cereal box so I can figger dis fcuker out" design.

Looks good.

[XLsior]

Originally Posted by cheesy

snort

Cardboard
Aided
Design



That's a hell of a lot classier than my "Gimme dat cereal box so I can figger dis fcuker out" design.

Looks good.

Well that method (FtFo)- figure this fucker out) at least give you more opportunity to try different breakfast cereals.


The CAD method is more cardboard on the brain until it falls out after much time wasted and you forgot to buy more cereal last week.

[XLsior]

Ate a box of Choco Pillows cereal...


Made the rough plan CAD battery box and transfered it of to sheet aluminum.


Had to trim down to fit and shave some edges but eventually got it mocked up and installed for a clearance test.


Rear tire clears without fear of contact. Enough under gap for chain and exhaust pipe.


I left side tabs to allow for the installation of the regulator and starter solenoid.


Also added the front wheel as counter balance but you get a closer idea of the end result.

[Bruces]

I like the blue paint .

[XLsior]

I will spare you the detail of flap discs and wire wheels prep..


Put in just enough effort to get the most of the flaky rust and treat it with converter, then hit with a spray of fresh paint.



Used Dunlop 605 on the rear along with the 45t sprocket. The tube survived. Most of the chrome on the rim was to far gone and the inner rim was a pitted mess but it is solid. So silver paint with zinc protect to the rescue.


The front rubber and tube I left alone, the rim is ok...spokes not great so wire wheel and more silver paint. then see if any loose spoke nuts turn...



Drum hubs got the flat black rustoleum 2x treatment.


No masking tape was used just accurate over-spray mitigation technique.



The lounge ornament is getting close to assembly under the house...Battery box and seat turned out alright.



Purchased a new header pipe and pitbike muffler (cheapest on Ebay)


Also new brake/clutch levers fro Aliexpress...

[XLsior]

Cobbling it all back together.


Considering how it looked when I got the 81 rolling frame, I think its turned out a considerable improvement.


Found a worn sprocket to make for a new kickstand foot.


Decided to drain the funky old fork oil.


The seat and tank will have to come off again for engine fitment...


But when the heart goes in it becomes a motorcycle again....