!984 Project - it begins

[aviationfred]

Reading through your thread, I see that you are repainting all of the body work. If you plan on owning this FJ for many many years, there is a fuel tank option that will eliminate a couple of issues. Mainly the gas cap. They are nearly impossible to locate replacements. I highly recommend locating a '86/'87 1200 fuel tank to use on your project. No modifications are required to the tank, petcock or carbs.


Fred

[TexasDave]

Just giving you a hard time Bob. Own one of those Hardly Ablesons myself. Keep us updated on your FJ project.

Dave

[FJ Bob]

Fred

Thanks for the info on the 1986/87 tank substitute. I did find a good gas cap which I have to swap the guts out of into mine so hopefully that will work.  I will keep an eye out for another tank though.

Dave

No problem with the HD ribbing, I ride with a group of non Harley folks and do get some good hearted teasing now and then.

More to come on the build but now I have to ready the Fatboy for winter.  The joys of living in Northern Ontario.

Bob

[FJ Bob]

Hi Everyone

Gas cap surgery tonight.  Below is a picture of the donor and the patient.  I'm pleased to report the patient survived and i now have a functional gas cap.

Bob

[FJ Bob]

More progress this weekend.

Replaced the left side controls as the chock control was broken.  Replacement unit went on nicely and works great.

I'm starting to fix up and sand the plastics in an effort to get then ready for new paint this winter.  Also started working on the tank as the previous owner had drilled a hole in the top and placed a bolt in it to assist in securing the gas cap down ( see pic below)  With the replacement gas cap working I've plugged the hole and will begin to smooth the tank for painting as well.

Lots of work to do but it is coming together nicely so far.

Bob

[FJ Bob]

Hi Everyone

Been busy cleaning up the plastics and the tank getting them ready for paint. 

I need to put two new tires on the bike.  I don't want to turn this into another tire thread but I'd like to know from my local Ontario riders which tires they use.

More pictures shortly on the progress.

Thanks

Bob

[PaulG]

I've used the Metzler Lasertechs BiasPly but currently am on Avon Storm 3D XM Radials.

The Metzlers are a decent all round tire with great mileage that are great for touring.  Being bias ply they tend to be a bit skittish over the tar snakes.  The Avon radials have a much smoother ride, but probably won't last as long as the Metzlers.  I've only had the Avons on for this season so far but really like them.

[FJ Bob]

Hi Everyone

Thanks for the info on the tires.

Here is the latest update.

Frame painted, plastics primed and below is a picture of some of the parts mocked up on the bike.  I'm going to stick with matte black for all the plastics.

I have an issue that maybe someone can help with.  I can seem to loosen the screws on the top of the front brake master cylinder.  I've tried penetrating oil and they just won't budge and I'm almost to the point of stripping the philips heads on the screws.  Any suggestions other than finding another master cylinder?

Thanks

Bob

[jscgdunn]

Hi Everyone

Thanks for the info on the tires.

Here is the latest update.

Frame painted, plastics primed and below is a picture of some of the parts mocked up on the bike.  I'm going to stick with matte black for all the plastics.

I have an issue that maybe someone can help with.  I can seem to loosen the screws on the top of the front brake master cylinder.  I've tried penetrating oil and they just won't budge and I'm almost to the point of stripping the philips heads on the screws.  Any suggestions other than finding another master cylinder?

1) Be sure you are using JIS screwdriver.
2) Use an impact driver. Here is combo:

https://www.youtube.com/watch?v=Q8QxPvDBJzE

Thanks

Bob

[FJ Bob]

Jscgdunn

Thanks!

That looks like the exact tool for the job.  Now to find out where I can get one in Canada.

Bob

[jscgdunn]

One on Amazon....this is the large one...for the master screws you would need the size (or two) down.
https://www.amazon.ca/s/?ie=UTF8&keywords=jis+screwdriver&tag=msncahydra-20&index=aps&hvadid=2371279532&hvqmt=p&hvbmt=bp&hvdev=c&ref=pd_sl_oyohbvvzx_p

[FJ Bob]

jscgdunn

Any idea what size of tip I would need.  I think that one on amazon is a #2

Also noticed that you Plasti dipped one of your bikes, I'm thinking that is what I'm going to do.  Were you happy with the results?

Thanks

Bob

[PaulG]

Make sure you replace the cap screws with these Allen head ones. RPM has them or you can pick them up just about anywhere.  My local Brafsco gave them to me for free.

master cal cap screws

[FJ Bob]

Paul

Thanks for the tip.  Once I get the screws out I'll do that.

Bob

[FJ Bob]

Jscgdunn

I did some additional searching and it looks like the Vessel JIS #2 Impact Driver is the right one so it is ordered.

Again thanks for your help.

Bob