Some pics of my FJ1200 project

[dma251]

http://steelsoldiers.com/showthread.php?16105-updated-pics-of-my-hemtt-restoration

Any chance of some pics of your finished truck resto? Link doesn`t allow me acces to the finished pics. I love this stuff. 

Here's a teaser pic.  You have to register on the site to see the progression.  It's got a lot of pics of this 3 year project that resulted in a $75000 sale.  It's worth the login if you're into these types of projects.  I've done three different army trucks ending with this big one.

[dma251]

Here's a shot from today.  I have hung the mufflers, but the header is not on.  I think I am going to paint the header and collector with light grey high-temp paint.  Some lightly contrasting color from the black. 

I have some welding to do on the subframe tomorrow.  I used heavy steel gussets as my mounting point for the subframe when I altered its position.  Unfortunately I was about a 1/4" off in my measurements and wound up needing to get creative....

Anyway, here's where I'm at so far...   

[rlucas]

Here's a shot from today...

Cripes, that garage is nicer than my kitchen.

rossi

[Joe Sull]

Thats looking really sharp. I went through painting my down pipes and collector with VHT fireproof. I put 2 coats of primer (one can) and 6 coats of color (two cans) I fired the primer on a wood stove in the winter then I sprayed the 3 coats of color and fired it by running the bike.
The first can didn't cover that good and I just sprayed on the second can last month. I fired that on the bike too. I lightly sanded the first application before spraying. I'll be replacing my manifold gaskets soon and when I do that I want to spray the clear coat fireproof.

[dma251]

Here's a shot from today...

Cripes, that garage is nicer than my kitchen.

rossi

Thanks for the compliment!  I had a pile of super-cheap laminate flooring, and to put it to use I laid it out in my garage.  Over three years it has been subject to every imaginable abuse including floorjacks lifting pickup trucks, frequent welding without ever a mark, jackstands supporting a lexus ls400, multiple oil, brake fluid, atf puddles.  Everything just wipes right off it.

Seriously, it is the best bang-for-your-buck improvement to your garage you can make.

The absolute BEST THING about it is this -  you can put your bike on the centerstand or sidestand, and then just slide it around on the floor into whatever location you want!   You just lift the back of the bike, and walk it around.  The floor makes it slide.

[dma251]

I realized that the best template for what the tail should look like on tis bike is the remnent of the seat.  

I really like the shape of the seat, and the way it is clearly two separate planes.  I was about to start building a cardboard model of a tailpiece, but I decided to play with the old half-seat instead and now new ideas are starting to flow....

[dma251]

Some of you might have noticed I am avoiding the absolute worst part of the FJ frame to deal with...   The headlight.

The front bar is in the worst of spots - right where a headlight naturally would be positioned.  I have a 7" chrome honda headlight/bucket that I have been coaxing my wife into holding in various positions.  None look quite right.

10 years ago I owned a 2001 Buell X1 White-lightning - the one with the cool powder-blue coated header pipe.  I've had almost a dozen bikes since then, but that's still at the top of the list for short-distance fun.
My FJ-project is heavily-influenced by that bike.  

Because of that, I have steered in the direction of a single large diameter chrome-rimmed headlight.  Unfortunately because of that damn bar, I need to find other solutions.

Maybe two smaller diameter headlights, but everyone has done that.   Maybe two stacked vertically, like the Ducati 999....   Kind of an Art-Deco-Locomotive design....

How about two headlights horizontally one large, one small Ala the BMW ?   Or, the "broke-down sportbike" headlight sticking out there all proud by itself?

I have considered going the hi-tech LED bar headlights.  Maybe even something vertical, like along the fork legs.   Problem is it doesn't fit the vintage style of the bike so-well....

I don't know...   My gut tells me that this is a simple, down-and-dirty standard, with a single, large-diameter round headlight, but how...

Sometimes I wonder if inevitably trends will swing around and maybe really large diameter headlights will become cool?

I could see a 9" or 10" flat-lensed headlight, LED of course, but behind a diffused lens, and with a black treated aluminum housing with matching fork mounts....

I know.  I'm dreaming...

[TexasDave]

Saw my first Honda ruckus scooter yesterday. It had a twin headlight setup on the front that looked good and put out a phenomenal amount of light. That naked FJ would look good with twins mounted on the front. That said I am an old guy who prefers the conventional look. Round clocks, round headlight and spoked wheels.  Dave

[dma251]

I love the Rukus!   Looks like riding a recliner down the road!

[TexasDave]

The guy who was riding it had the passenger seat folded up for a backrest. He said it was only 250cc but it would get down the highway. The guy riding with him wanted the same headlight setup for his bike but said Honda wanted $300 for the lights and bracket. Didn't look like it would be to hard to fabricate.  Dave

[fintip]

Some headlight ideas others have tried:

fjowners.wikidot.com/naked

I used to think it was impossible, but some people have come up with some good looking options. Hope that helps with inspiration. Yours looks great, keep it up. 

[giantkiller]

Just a quick thought. What about cutting the housing slightly too fit around the bar and clamp around the bar on the inside. that way you could rotate it for up and down adjustment.

[dma251]

I'm still procrastinating about the headlight and am more focussed on the tail and electrical right now. 

I have removed all the nonessential wiring from the harness and relocated the TCI box and all the relays to the rear of the bike/harness.   

I am going to make a harness support bracket that will carry the harness right down the center of the fuel tank, leaving it mostly out of sight.  It will travel over the carbs and into the shallow pan under the seat that I welded in today.  I chopped up an old service-van shelving unit and used the steel to enclose the tail.   I ran out of gas for my mig welder, so I had to switch to flux-core, which doesn't make my already ugly welds any prettier.    Before I paint I will seal the edges with body-seam sealer, and will cover them up...   Not my usual method, but I don't want to see welds anyway. 

Check it out....

[dma251]

I have been playing around with the bar position the last couple of nights because it just didn't look right with the high-riding FJ clip-ons.   I tried a few different things with them, including sliding them down below the tripleclamp.    That got them to the right position, but they hit the tank.

It's official.  I can't work with the old risers.   Need clip-ons.  I removed the heated grips and the throttlemeister, as I don't need any of that for this bike.  It will never be comfortable enough to need a cruise control or warm hands.   This is a different kind of FJ 

I have given myself a strict mandate that this project not exceed $1000, and I've spent a hair past $500 already including the bike, so I need to make some parts pay for others.  The Throttlemeister sold and turned into this set of used Woodcraft clipons.

http://www.ebay.com/itm/171357651847?item=171357651847&viewitem=&sspagename=ADME:L:OC:US:3160&vxp=mtr

When they arrive there will be some more pics!

[Joe Sull]

I tried lightening this picture to maybe give you some ideas. If that piece of the frame that goes around the front of the steering head wasn't there, it would make things a lot simpler.