Mailmans , 77D getting a makeover

Nice write-up Bob. I know what you are saying when you say "On the 77D, you sit up high, you definitely have the sensation of being on top of the bike, the handlebars are also lower." Funny, I didn't remember this in 1977...haha, when I bought a new D model, but it is kind of a new ridding position from the bike I have (1988 NT650 Honda) and have the ones previously. It is very tall, but flicks around fairly easily. It just is going to getting use to.
I have some vacuum gauges and might try your system of tuning the carbs.
I did notice how much better your XS2's front fender fits the tire than the '77's front fender though.
 
Thanks Gator!

Nice write-up Bob. I know what you are saying when you say "On the 77D, you sit up high, you definitely have the sensation of being on top of the bike, the handlebars are also lower." Funny, I didn't remember this in 1977...haha, when I bought a new D model, but it is kind of a new ridding position from the bike I have (1988 NT650 Honda) and have the ones previously. It is very tall, but flicks around fairly easily. It just is going to getting use to.
I have some vacuum gauges and might try your system of tuning the carbs.
I did notice how much better your XS2's front fender fits the tire than the '77's front fender though.

Thanks Tom, yeah I’ve never tried vacuum gauges, I’ve read before that they might flutter a lot? I don’t know, but if it comes to it, a manometer like mine only costs a few bucks to make, and they work really well. You can hear the engine smooth out when the carbs synch up.

Your white gas tank is the perfect basis for another project. It even has the key!! Go ahead, step up and "Take the Plunge" :devil:

You’re gonna get me in trouble! Haha! :laugh2: I can hear the conversation already, “ But honey.....I’ve already got the tank!”

Good comparison Mailman and very beautiful looking bikes. JC

Thanks JC, I appreciate it!
 
Ha! My head keeps telling me I’m still 20 years old. My back says “ Hold on there cowboy! “ :D

G'day Bob,

Since I have started riding my '76 seriously now it just astounds me on the acceleration, you just twist the loud RH wrist and it pulls like a 14 year old, LOL.

Still known as "Puff" as I cannot find that freaking engine oil leak.

Yup first couple of rides felt very different to my '94 BMW R1100RS as on the XS you do sit on top so to speak however, it is such a light machine that you can drop it into a corner (once you gain confidence) and it just comes out the other end and seems to want more.

I cannot keep my arse of it now.

GDub
 
Real shame about the original tank but then it probably galvanised you into doing something with the old gal.;)

I would be tempted to use a hair dryer or wallpaper stripper to heat that dent and the surrounding area then give the center of the dent a good blast of icy cold aerosol like aerosol dust spray or something safe . I bet that dent would pop straight out ;)

The proposed new colour scheme looks very classy...... mind you it reminds me a bit of the UPS parcel vans ...ahem...:whistle:..... moving swiftly on...

I like the grips idea ,,, I use something similar on my classic Lambretta and I find them comfy and supportive , they fit into the palms like a computer mouse .
 
Real shame about the original tank but then it probably galvanised you into doing something with the old gal.;)

I would be tempted to use a hair dryer or wallpaper stripper to heat that dent and the surrounding area then give the center of the dent a good blast of icy cold aerosol like aerosol dust spray or something safe . I bet that dent would pop straight out ;)
.

I've tried using a heat gun and a cheap dent puller to remove some minor dents from my '78 tank without success. I even tried the aerosol trick too. It is surprising how thick the steel is on these tanks. I did have limited luck on a 75 tank on the large flat side though. Not saying that a Paintless Dent Repair specialist couldn't do it, but I think these tanks require a little more force from the inside prying out to pop the dents out. But that's just my experience.
 
I have seen it done sucessfully but It looks like you need to really heat up the metal very hot and then use a sudden blast of freezing gas to shrink the metal back to its original molecular structure. Most folk probably don't supply sufficient heat afraid they might damage the paint but the sun can heat car panels to incredible temperatures.
I may try it on a dent on my van when the rain stops. i've also bought some pullers as well .
 
Pete, that would be an interesting comparison between the SV and the XS.

GDub, I’m happy to see you getting some seat time on “Puff” ! :)

Your '77 looks great, Bob !

Thanks Jeff!


Regarding the dent in the white gas tank, if it were a shallow dent with a rounded shape, it might pop out, but when the bike fell over it hit the corner of my bike lift and put a sharp crease in it. Even though it is relatively shallow, it would take some work to remove it. If you’ve never seen how they do paintless dent repair on motorcycle gas tanks, here’s a good little video. Prepare to be amazed.
 
Regarding the dent in the white gas tank, if it were a shallow dent with a rounded shape, it might pop out, but when the bike fell over it hit the corner of my bike lift and put a sharp crease in it. Even though it is relatively shallow, it would take some work to remove it. If you’ve never seen how they do paintless dent repair on motorcycle gas tanks, here’s a good little video. Prepare to be amazed.

I've seen videos like that before and was always amazed at how simple they make it look! But that is how it is when you watch someone with skill it always seems simple till you try it yourself!
 
I seem to remember paintless dent removal started out as almost a secretive cult like thing. Maybe a franchise that would train you and had all kinds of restrictions on what you were allowed to tell about it?
 
I seem to remember paintless dent removal started out as almost a secretive cult like thing. Maybe a franchise that would train you and had all kinds of restrictions on what you were allowed to tell about it?

There are a bunch of videos from a training school on YouTube, and you’re right, they want to sell you on taking their courses. I tried to find any outfit here in Phoenix to do it, but no luck. There don’t seem to be that many places that do it.
 
I'm new to the board. But was floored when I watched this video. I had pro PDR repair a ding on my truck just days before the first show. They were awesome to deal with and very talented.
 
One of my buddies here tried to get a place to fix a tank dent and they want huge money to do it.

Any clue as to how much that job on the Honda CB550 tank might have cost?

Pete
 
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