Hey all,
I thought I might share what I hope is the final push in a 3 phase restoration of my 87 FJ.
Phase 1 was in April 2014 - Getting it running again - see here for my intro: http://www.fjowners.com/index.php?topic=11247.msg113079#msg113079 (http://www.fjowners.com/index.php?topic=11247.msg113079#msg113079)
Phase 2 was in July 2015 - Upgraded the wheels and suspension - see here for that post https://fjowners.com/index.php?topic=14281.msg144100#msg144100 (https://fjowners.com/index.php?topic=14281.msg144100#msg144100)
Phase 3 now in Sept 2022 - Yea, there is a 7 year gap here. Finally back at it, and hopefully this is the last major renovation for a while.
Goals for this final phase are to:
1. fix a valve that is too tight even on the smallest shim (@Randy is expecting to get my head soon)
2. powder coat all the silver and black metal bits including the frame and fork lowers
3. fix all the dinged/cracked/damaged plastic and paint it with the original colors and decals (rddecals / color-rite)
4. fix some electrical issues mostly having to do with old connectors
5. fix any other loose, damaged, scratched, worn parts as I find them
6. throw on some new accessories like a larger oil cooler, led tail light etc. (here I come Randy!)
I thought you guys might like to see a few pics of the tear down this weekend
(https://fjowners.com/gallery/12/medium_4000_12_09_22_11_22_54_0.jpeg)
(https://fjowners.com/gallery/12/4000_12_09_22_11_22_56_2.jpeg)
(https://fjowners.com/gallery/12/medium_4000_12_09_22_11_22_58_4.jpeg)
The last phase should keep me busy this winter I hope. I'll try to keep this thread updated with progress.
You all usually have such great advice, so if you see an opportunity to repair or upgrade something while I am in here, please let me know![/list]
Slow progress ,but your bike look very nice! Really like the colors on it :good2: here in Norway it was not sold in that colors the red and white was placed opposite way or they where blue and white
Quick update as of 9/22/22
Metal bits are at the powder-coating shop. It's going to be more expensive than I thought. Probably north of $700 to blast and re-paint everything.
(https://fjowners.com/gallery/12/4000_22_09_22_3_38_42_0.jpeg)
The head is in RPM's competent hands. Randy is tipping the valves to resolve one valve that is too tight, and will put all the rest right in the middle. We'll install new valve seals and check that we have a good seal everywhere else. He has my order for about every part than I haven't bought from him yet. :-)
(https://fjowners.com/gallery/12/medium_4000_22_09_22_3_40_19_0.jpeg)
I've started on the body work repairs - front the ground up. Below is the chin scoop. The clutch master cylinder had a leak for years and brake fluid oozed onto the left side of the chin scoop, weakening the plastic, eventually breaking off. I cleaned it all up, and I'm using .125 thick sheets of ABS plastic from Amazon and some ABS cement to laminate 2 pieces together and attach a new trailing piece onto the left side of the scoop. It's not done yet, but I am happy with the way it's coming along.
(https://fjowners.com/gallery/12/4000_22_09_22_3_27_17_0.jpeg)
(https://fjowners.com/gallery/12/4000_22_09_22_3_27_18_1.jpeg)
Thought you all might be interested. Once I finish with the scoop, I'll share paint ready pics here and move on the the other parts.
Got my metal bits back from the powder coater today! Im really happy with the way they turned out!
(https://fjowners.com/gallery/12/medium_4000_17_10_22_9_38_33_0.jpeg)
The plan is to re-assemble most of the frame now, and fit the repaired plastic parts to the frame before painting the plastic.
For example, I am having to create new tabs for the front fender.
I need to put these on the forks in order to determine exactly where to drill the holes and how to shape the remaining plastic around the holes.
(https://fjowners.com/gallery/12/medium_4000_17_10_22_9_44_07_0.jpeg)
(https://fjowners.com/gallery/12/medium_4000_17_10_22_9_44_08_1.jpeg)
Also here, where I had to rebuild the left, aft fairing. I need to put the fairing on the frame to put the new holes in the correct location
(https://fjowners.com/gallery/12/medium_4000_17_10_22_9_48_08_0.jpeg)
(https://fjowners.com/gallery/12/medium_4000_17_10_22_9_54_01_2.jpeg)
(https://fjowners.com/gallery/12/medium_4000_17_10_22_9_54_00_1.jpeg)
(https://fjowners.com/gallery/12/medium_4000_17_10_22_9_53_59_0.jpeg)
Nice work....lots of patience needed im thinking ????
Ok, the front fender tabs are finally done.
Here is the final fitment before the body filler to make it pretty
(https://fjowners.com/gallery/12/medium_4000_22_10_22_6_47_30_0.jpeg)
And here it is after the body filler made it look better
(https://fjowners.com/gallery/12/medium_4000_22_10_22_6_47_31_1.jpeg)
(https://fjowners.com/gallery/12/medium_4000_22_10_22_6_52_02_0.jpeg)
Here is the chin scoop mounted for final fitment
(https://fjowners.com/gallery/12/4000_22_10_22_6_52_04_2.jpeg)
(https://fjowners.com/gallery/12/medium_4000_22_10_22_6_52_05_3.jpeg)
Here are the fairing repairs all filled in
(https://fjowners.com/gallery/12/medium_4000_22_10_22_6_52_03_1.jpeg)
And the tank in progress. Had several little dings etc that I first pushed out from the inside, then used body filler to make it perfect.
(https://fjowners.com/gallery/12/medium_4000_22_10_22_6_52_06_4.jpeg)
I think the body work is about ready for paint
(https://fjowners.com/gallery/12/medium_4000_22_10_22_6_47_32_2.jpeg)
It's a good thing, because Randy just provided a return shipping tracking number for the head. In addition to tipping all the valves to use the same shim, I had 1 burned valve, 4 worn valve guides and several cam caps needed helicoils. Thank goodness we got those things fixed up.
One other note.. The bike has a 1250 big bore kit in it. I figured that I would never, ever be able get rings or pistons again. But Randy pulled some strings with Wiesco and the literally manufactured a new set of 1250 rings for us!
Randy is also shipping me a bunch of other goodies like an oil cooler etc. I cant over-state how great RPM and Randy have been for my FJ. Thank you!
Quote from: Urx on October 18, 2022, 01:46:44 AM
Nice work....lots of patience needed im thinking ????
You know, normally I am a pretty impatient person. Im usually trying to get the bike back together to clean up the garage or go for a ride. That makes me rush things.
But I have resolved myself that this will take all winter. Also, this time, I have enough space in he garage to leave it apart all winter. I also have other bikes to ride. So, I can work on it just a few hours per week and still make progress.
This body work, especially manufacturing new body parts to fix the broken OEM body work, is indeed tedious. But it is also pretty satisfying to see the old girl getting back into fighting shape.
Thanks for looking!
Quote from: Old Rider on September 12, 2022, 12:51:37 PM
Slow progress ,but your bike look very nice! Really like the colors on it :good2: here in Norway it was not sold in that colors the red and white was placed opposite way or they where blue and white
Thanks so much. I love these colors too. I remember the first day I saw this FJ in person, it was 1988 and the thing was so regal and classy, yet strong and sexy, I just had to own it. The 87 red/white paint scheme is by far my favorite.
Nice job Pete! Your care and attention to detail will pay off. She's gonna be a beauty when finished.
Question on body filler, aka: Bondo, I recall that a special mix or type of filler is needed in areas that might experience vibrations. This is done to prevent cracking. Do you have any info. on this?
Cheers Pete, keep the update photos coming, I love to see these restoration projects.
You know, that is a good question. I normally use this stuff: https://www.amazon.com/dp/B00GQ1X1MQ?psc=1&ref=ppx_yo2ov_dt_b_product_details (https://www.amazon.com/dp/B00GQ1X1MQ?psc=1&ref=ppx_yo2ov_dt_b_product_details) for filling in pin holes and really small imperfections in my plastic welding repairs. I don't think that Icing is intended for flexing parts. Yet, I used it on the front fender, with more buildup than I have would typically use (probably 1/16" thick right in front of the new bracket abs). :Facepalm:
It will be interesting to see how this wears... If there is any plastic on the bike that sees a lot of vibration, it's that front fender. That said, all the shaping is done and I don't think I have the patience to cut it out and start over with new filler... Instead I'll probably just paint it and see what happens. If it cracks, It wont be too hard to cut the filler out and use some flexible filler and re-paint it. The fender is just one color and super easy to remove & repair.
Thought I would post a short update today.
I received the cylinder head back from Randy and it looks great! I am currently working on honing the cylinders and removing carbon from the pistons so that I can install the new rings and put the engine back together.
In other news, I have looked and looked for a painter who is willing to spray the old girl. Ive done all the repairs and prep work, and still, the only quote someone was willing to give me was for $6,000!! WTF! Looks like I'll be painting her myself in a makeshift visqueen paint booth I create in my garage. Ive done this before and its a bit of a pain, but its worth $6000 to me to do it myself. I'll be sure to capture progress on this as it goes.
Have a great weekend all!
check out the race forum like WERA. We are always repainting fairings and such. I've used DC paintworks in Easton PA. $400 for the last set (no tank).
Quote from: Motofun on November 04, 2022, 06:57:03 PM
check out the race forum like WERA. We are always repainting fairings and such. I've used DC paintworks in Easton PA. $400 for the last set (no tank).
Thanks for the suggestion. $400 is a great price!
But, I just ordered the paint today from https://vmrpaints.com/. (https://vmrpaints.com/.) It was $575 delivered for a quart each of primer, base coat, color coat and clear coat. That's not too bad, about $100 cheaper than color-rite. They have colors for Yamaha Silky White, and Yamaha Stormy Red. I actually think the '87 used "Passion Red" as per http://www.fjowners.com/index.php?topic=2902.0. (http://www.fjowners.com/index.php?topic=2902.0.) Comparing pictures of 86 vs 87 FJs, I think Passion Red is just a little darker than Stormy Red, but none of the paint distributors have a code for that. So, mine will be Stormy Red I guess.
Yep, Stormy Red rocks!
I'm going by memory but *I think* Stormy Red was used only on the '84's and the darker Passion Red's were used on the 85-87 FJ's.
My '85 is stormy red
Quote from: Motofun on November 05, 2022, 06:28:50 AM
My '85 is stormy red
Makes sense, 84/85 both Stormy Red...and just the red/silver combo on the '84 USA bikes.
Time for another update. Some bad news / good news in this post.
So as mentioned above, RPM sent the head back, all fresh and new. They also sent a new set of 1250 rings, made just for me... But...
I hadn't looked closely at the cylinder bores yet. Originally, I had NOT planned to replace the rings. But I thought as long as RPM has a hook up with Wiesco, why not replace the rings for good measure. So I looked at the bores closely and you can see this before honing picture of the #1 hole.
(https://fjowners.com/gallery/12/medium_4000_19_11_22_11_22_17_0.jpeg)
Yea, not pretty. I was hoping that she'd "buff right out" when I honed the cylinders, but post hone, it looked like this:
(https://fjowners.com/gallery/12/medium_4000_19_11_22_11_22_18_1.jpeg)
Post hone, it's not TERRIBLE, but still not right. There is an old timer rule of thumb that says if a score on the cylinder can be felt by your fingernail, you have to bore the cylinder. I could just feel the scoring. Honestly, I was tempted to ignore this and slap it back together. After all, there is a good chance this bike wont get another 10,000 miles in its lifetime. I'm really just restoring my teenage bike for my private therapy, for posterity and as a hobby. I thought, as long as the bike doesn't smoke, it will probably be OK.. But at the same time, it didn't feel right. Even if it doesn't smoke, I'd always know that I cut that corner, and it would grind on me.. After all, I'm not in a hurry, and I am not broke teenager anymore, so why not fix it correctly?
So, I sent RPM the before/after pics. They immediately told me that scoring on the upper portion of the bore like that is an indication that piston is rocking in the bore because the bore is too big for the piston. Additionally, they noticed that the scoring is not on the front / aft of the bore, it's slightly on the side. This is an indication that the rod might be bent! Also, the new 1250 rings were way too big - using them would have required that I cut them down by at least 1mm. Holy crap, this project is getting deeper. So I packed up the jugs and pistons and sent them to RPM for inspection.
This is a good time to tell you about some history on the engine and the #1 cylinder. In 1995-1996, I paid a shop to work over the head, put larger valves in it and do some mild porting. I also had them bore it for a high compression big bore kit. While it was apart I had the transmission magna-fluxed and back cut the dogs to prevent 2nd gear pop outs. Shortly after I put it back together, I was on an overnight ride from Utah to Colorado and the engine blew up in Mack, Co. My future wife at the time drove through the night to rescue me and my dad rode over from Colorado to keep me company. The next year I wrote a short story about the event for a college writing class. The story is just 4 pages and might be of some interest to anyone who rides with their Dad or Son. https://docs.google.com/viewer?a=v&pid=sites&srcid=ZXBldGVyc29ucy5jb218d3d3fGd4OjJjODVmMmQyYzRmYWJiZGY (https://docs.google.com/viewer?a=v&pid=sites&srcid=ZXBldGVyc29ucy5jb218d3d3fGd4OjJjODVmMmQyYzRmYWJiZGY). After the engine blew up, I took it apart and discovered that in intake valve in cylinder #1 broke and the valve face fell into the cylinder at 6000 RPMs. Wow, it really messed up that cylinder. The shop agreed to do the labor if I bought the parts to repair. In retrospect, I think the repair job was half assed and that was the cause of the over-tight valve that drove the head work during this restoration. It also might be the cause of the bores being too big and the rod being bent.
So our friends at RPM got back to me and shared a few amazing pieces of information.
1. The piston / bore clearance was .007" (4x bigger than the max allowed of .002)
2. The wear on piston #1 confirmed that the rod is bent (holy cow, Randy and Robert are AWEOME)
3. The reason the rings didn't fit is that it's actually a 1219 kit with stock sleeves, rather than a 1250 as I am pretty sure the shop told me they were installing back in the day
The repair options were
1. Go with an RPM 1250 kit and use all new pistons and cylinders OR re-sleeve the existing block with OEM sleeves and re-bore them to fit the existing pistons, then install new rings
2. For the bent rod, put 4 new high performance rods in or get some used rods and have the big end bearing re-ground to remove any egg shaping.
For this restoration project, my priorities on decision making on repairs are in this order: a) do it right for safety & reliability b) re-use original parts as much as possible for posterity and c) choose the lowest cost option (rather than high performance).
So, that means I'll have RPM put new OEM sleeves in and re-use the 1219 pistons. I found 4 used rods from an '86 on ebay for $20 shipped, I had those sent straight to RPM, who will make sure they are straight and re-size the big end bearings to remove any egg shaping that occurs on OEM rods. RPM is also starting work on re-sleeving the jugs. Robert even said that they are able to shave the piston crowns down slightly to lower the compression back to near OEM compression levels so that I can run pump gas safely. I'll say it again, this project COULD NOT HAPPEN without Randy and Robert at RPM. I am so impressed with them that I just cant say enough good about them.
Final picture today is the engine cases split so that I can install the refurbished rods and new crank journal bearings while I have it apart.
(https://fjowners.com/gallery/12/medium_4000_19_11_22_11_22_19_2.jpeg)
Happy weekend everyone.
I found a couple of old pictures relevant to the day I broke down in Mack, Co
The Gas station in Mack, CO where I was stranded after the breakdown. (taken in 2000)
(https://fjowners.com/gallery/12/medium_4000_19_11_22_2_14_39_1.jpeg)
August 1996 - My wife (girlfriend at the time) when she was rescuing the FJ and me.
(https://fjowners.com/gallery/12/medium_4000_19_11_22_2_14_38_0.jpeg)
You can be assured it will run as well as it'll look too!
Nice job keeping the project rolling over time :drinks:
Quote from: fj1289 on November 19, 2022, 02:36:09 PM
You can be assured it will run as well as it'll look too!
Nice job keeping the project rolling over time :drinks:
I agree, and thank you!
It's been a while since my last update. In the winter of 2023, RPM returned my cylinders with new 1mm over sleeves, some new rings, and refurbished rods.
I was able to soda blast all the engine cases and Cerakote them in my DIY oven.
Here are a few pics of the painting process. Note the diy paint booth and oven! It turned out really well.
(https://fjowners.com/gallery/12/4000_10_02_24_5_26_02_2.jpeg)
(https://fjowners.com/gallery/12/4000_10_02_24_5_26_01_1.jpeg)
(https://fjowners.com/gallery/12/4000_10_02_24_5_26_00_0.jpeg)
(https://fjowners.com/gallery/12/4000_10_02_24_5_26_03_3.jpeg)
(https://fjowners.com/gallery/12/4000_10_02_24_5_26_04_4.jpeg)
Then I assembled the crankcase. Then the project sat for about a year.
I spent that time doing a lot of adventure riding on other bikes and playing with other hobbies.
As you can see here, my grandson got accustomed to making motorcycle sounds in the empty FJ frame.
(https://fjowners.com/gallery/12/4000_10_02_24_5_26_06_6.jpeg)
(https://fjowners.com/gallery/12/4000_10_02_24_5_26_07_7.jpeg)
I just got rolling on the project again in Jan 2024. I put the top end together and installed the engine in the frame.
I took this time to replace a bunch of junky connectors on the wiring harness and fix some crappy butt splices etc.
I also freshened up the carbs again, making sure everything was squeaky clean.
(https://fjowners.com/gallery/12/4000_10_02_24_5_26_08_8.jpeg)
(https://fjowners.com/gallery/12/4000_10_02_24_5_26_09_9.jpeg)
(https://fjowners.com/gallery/12/4000_10_02_24_5_31_00_0.jpeg)
Today was run day - she fired up and after fixing a few small oil leaks etc, she settled down into a nice idle and ran smoothly.
Here are a couple of quick vids of it running and carbs sync.
https://photos.app.goo.gl/C2EamTS1jpPScV6C6
https://photos.app.goo.gl/NVBKers1ayQFGExD9
Now it's time for body paint. Just doing the last bit of sanding on the tank, and I should be able to get the painting done over the next couple of weeks.
Hopefully this girl will be ready for the 2024 season in time for the warmer weather.
(https://fjowners.com/gallery/12/4000_10_02_24_5_31_01_1.jpeg)
Thought I would add a little extra detail about a fix I made to the carb enrichener (choke) plungers. Not sure if anyone else has or had this issue.
After 64k miles the choke rod that runs horizontally through all 4 carbs wore the hole in the carb bodies into an egg shape
(http://)
This allowed the rod to rattling around, wearing out the $50/ea enrichener plungers and an unacceptable rate.
(https://fjowners.com/gallery/12/4000_11_02_24_1_10_19_2.jpeg)
To fix this, I bought a long 6mm drill bit (https://www.amazon.com/dp/B0B1Q8JTZN (https://www.amazon.com/dp/B0B1Q8JTZN)) and some brass tubing 5mm ID and 6MM OD (https://www.amazon.com/dp/B08ZYKL16M (https://www.amazon.com/dp/B08ZYKL16M)).
I ran the drill through all 4 carbs, then inserted 1" wide sections of the brass rod into the now 6mm holes. One of the carbs was worn enough that it required a little JB Weld to hold the brass insert tight.
(https://fjowners.com/gallery/12/4000_11_02_24_1_10_20_3.jpeg)
(https://fjowners.com/gallery/12/4000_11_02_24_1_10_21_4.jpeg)
Now things are nice and snug. Hopfully this will slow/stop the wear on the plungers.
(https://fjowners.com/gallery/12/4000_11_02_24_1_10_22_5.jpeg)
TBH, they may a little too snug actually, I think I may add an additional return spring on the end of the rod or on the choke cable to push the enricheners fully closed when the cable is released. I'll let you know how that works out.
Ok, time for another mini update!
I got my temporary paint booth set up
(https://fjowners.com/gallery/12/4000-050324200458-01030.jpeg)
And did some spraying (any praying)
(https://fjowners.com/gallery/12/4000-050324200506-125662044.jpeg)
(https://fjowners.com/gallery/12/4000-050324200518-125681351.jpeg)
Here are a few images of the finished parts
(https://fjowners.com/gallery/12/4000-050324200509-125672064.jpeg)
(https://fjowners.com/gallery/12/4000-050324200536-12570400.jpeg)
(https://fjowners.com/gallery/12/4000-050324200538-125712004.jpeg)
(https://fjowners.com/gallery/12/4000-050324200532-12569703.jpeg)
If you ever see my girl parked, don't look too close or you will surely see some small mistakes. However, it should look good enough during a fly-by!
Next up, zinc plating some of bolts that still look rough, then a break-in ride! Just in time for spring!
Looking really good. :good2:
Well, phase 3 is pretty well wrapped up. Just need to do the break-in ride and polish a few things up. I've actually surprised myself, realizing that I am a little anxious about riding it now... Because I know that it will just start to degrade again from here. It's snowing here in Omaha, NE today, so I can just stand around looking at her for now, which is fun all in itself.
Just wanted to say thanks to all the encouragement and support from this group over the years! Kookaloo!
(https://fjowners.com/gallery/12/4000-080324153950-12572132.jpeg)
(https://fjowners.com/gallery/12/4000-080324153954-125751384.jpeg)
(https://fjowners.com/gallery/12/4000-080324154011-125772414.jpeg)
(https://fjowners.com/gallery/12/4000-080324154003-125761877.jpeg)
Very well done! :drinks:
Bellissimo! Better than new......... way better than new! Spring is coming!
Very nice. Lot of hard work gone into that, enjoy
Very nice ! :good2:
Thanks guys!!!
Quote from: petetb154 on November 19, 2022, 02:22:51 PMI found a couple of old pictures relevant to the day I broke down in Mack, Co
The Gas station in Mack, CO where I was stranded after the breakdown. (taken in 2000)
(https://fjowners.com/gallery/12/medium_4000_19_11_22_2_14_39_1.jpeg)
August 1996 - My wife (girlfriend at the time) when she was rescuing the FJ and me.
(https://fjowners.com/gallery/12/medium_4000_19_11_22_2_14_38_0.jpeg)
Hey, I've been to that gas station!
Quote from: Chainlube on March 14, 2024, 12:45:46 AMHey, I've been to that gas station!
No kidding! It's not very remarkable, other than it isn't. I spent the night on the side of that building in 1996!