87 (1TX) restoration - the final push?

[petetb154]

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
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
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

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]

[Old Rider]

Slow progress ,but your bike look very nice! Really like the colors on it  here in Norway it was not sold in that colors the red and white was placed  opposite way or they where blue and white

[petetb154]

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. 


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. :-)


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.



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.

[petetb154]

Got my metal bits back from the powder coater today! Im really happy with the way they turned out!



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.



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

[Urx]

Nice work....lots of patience needed im thinking ?

[petetb154]

Ok, the front fender tabs are finally done.

Here is the final fitment before the body filler to make it pretty


And here it is after the body filler made it look better



Here is the chin scoop mounted for final fitment



Here are the fairing repairs all filled in


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.


I think the body work is about ready for paint


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!

[petetb154]

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!

[petetb154]

Slow progress ,but your bike look very nice! Really like the colors on it  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.

[Pat Conlon]

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.

[petetb154]

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 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).

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.

[petetb154]

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!

[Motofun]

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). 

[petetb154]

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/. 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. 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.

[Pat Conlon]

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.

[Motofun]

My '85 is stormy red