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Jim's 1980 SG Restoration. And Yeah.... A Few Mods.

Discussion in 'The Garage' started by Jim, Sep 26, 2017.

  1. Jim

    Jim Beyond the edge, is the unknown. Here be Dragons XS650.com Supporter Top Contributor

    Thanks for the info!! I'll definitely check em out.
     
  2. Jim

    Jim Beyond the edge, is the unknown. Here be Dragons XS650.com Supporter Top Contributor

    Awesome heads up there Skull. Just ordered piston ring set. 25 bucks for both pistons. If I remember correctly, Mikes XS wanted 35 bucks per piston.
    30K parts sold with a 99.5 rating... About as close to a sure bet as you can get. I owe ya one Bro:D
     
  3. Jim

    Jim Beyond the edge, is the unknown. Here be Dragons XS650.com Supporter Top Contributor

    Ok. so I noticed on other threads that they were using thumbnails instead of full size pics and the thumbnails bring up the full size image. I'm playing around here and now understand how to do that (new guy, remember...). Whats more commonly accepted here, full size or thumbnails?
     

    Attached Files:

    Last edited: Sep 27, 2017
  4. mrtwowheel

    mrtwowheel Honda Etched On Brain Top Contributor

    I don't think it matters on this awesome modern website. It may matter to the guy in rural Canada using dial up internet and windows 98. Please don't use photo bucket.

    Scott
     
    Jim likes this.
  5. 5twins

    5twins XS650 Guru Top Contributor

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    I use full size but I crop and re-size the pics first so they don't overwhelm the post. I use a simple little free program. It makes doing those 2 operations easy .....

    http://www.5dfly.com/free-photo-editing-software/

    My "doctored" pics are stored on my computer of course, but also online to ease posting them. Some are on the site here, the rest (majority) on a 3rd party site (imgur at the moment). I did use photobucket for years until they pulled the rug out from under us, the greedy bastards, lol.
     
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  6. Jim

    Jim Beyond the edge, is the unknown. Here be Dragons XS650.com Supporter Top Contributor

    This is messed up.... I'm retired and now spend way too much time on "honey do's". :) Heh... like I didn't see that one coming. Anyway, cleaned the jugs up today. Both sides mic'd out well within limits. Barely worn at all. It's been sittin in a stoddard tank for about three days now. Still looked pretty nasty.
    IMG_20170929_164106943.jpg
    Bead blasted it, blew it out and washed it about a gazillion times. Honed to about a 50-60 degree crosshatch, washed again, bagged it and put it on the shelf, ready for reassembly.

    IMG_20170929_193237047.jpg IMG_20170929_193251294.jpg IMG_20170929_193349509.jpg IMG_20170929_193548529.jpg

    Thought I'd try the thumbnails and see how that works. After I get my "honey do's" done tomorrow, I'll start on the pistons.
    Jim.
     
    Last edited: Jan 31, 2018
  7. Mailman

    Mailman Hardly a Guru Top Contributor

    Looking good there Jim! You are trucking right along on this build. It's clear you know which end of a wrench to hold! Carry on, I'm enjoying this, and you are taking good photos too.
     
    Jim likes this.
  8. Jim

    Jim Beyond the edge, is the unknown. Here be Dragons XS650.com Supporter Top Contributor

    Thanks Mailman!
     
    Last edited: Sep 29, 2017
  9. Jim

    Jim Beyond the edge, is the unknown. Here be Dragons XS650.com Supporter Top Contributor

    Got the pistons done today.
    Almost forgot to take a "before pic". Pistons in my homemade stoddard tank...
    IMG_20171001_155138952.jpg
    After scraping off the carbon and cleaning out the ring grooves, they cleaned up pretty good with some elbow grease and scotchbrite pads.
    IMG_20171001_155251723.jpg
    Bead blasted the skirts and put a molykote finish on them. Air dried the moly for 30 min. then baked at 300 for 2 hrs.
    IMG_20171001_180040800.jpg IMG_20171001_180046270.jpg
    Before and after mic. shows about a 1 thousands coating. As soon as I get my T gauges back, I'll check piston clearances, but I'm pretty sure they'll be just fine.
    Next up, the head.
    Jim.
     
    Last edited: Jan 31, 2018
    Boog and TwoManyXS1Bs like this.
  10. Jim

    Jim Beyond the edge, is the unknown. Here be Dragons XS650.com Supporter Top Contributor

    I also started playin around with the side covers. They were pretty rough...
    IMG_20170829_192024938.jpg IMG_20170829_192030462_HDR.jpg
    Used a scotchbrite disc on a die grinder to remove old clear coat and corrosion, then wet sanded with 400, 800, 1000, and finally finished off with white jewelers rouge and buffing wheel. Sweet!!
    IMG_20170831_151753815.jpg IMG_20170901_091055129.jpg
    Jim.
     
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  11. Mailman

    Mailman Hardly a Guru Top Contributor

    Jim, you really do impressive work. You must be putting in some serious time out in the garage.
    Your metal polishing is terrific. I like to learn, care to detail your polishing process?
     
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  12. Jim

    Jim Beyond the edge, is the unknown. Here be Dragons XS650.com Supporter Top Contributor

    Thanks Mailman. It's pretty straight forward really. After a good washing, I start with a scotchbrite disk on a die grinder. I like a 90 deg. grinder, but that's a personal choice. Use as fine a grit as gets the job done. Any coarser just creates more work. Keep it moving, staying in one area just makes the surface irregular and bumpy. Once all the bad areas are gone, start wet sanding with a good quality (3M) sandpaper. Use LOTS of water. Dunk in a bucket or use a garden hose.Try with 400 to start. You might have to go down to 320 or 220 but see if 400 works before doing that. as much as possible, sand in one direction. That way you'll be able to see when the next finer grit makes the previous grits sanding marks disappear. Always change directions when you change grit. Once you get to 800-1000, use a buffing wheel and jewelers rouge. The white seems to work best for aluminum. That's about it... It's slow, tedious work that goes faster when you lubricate yourself with lots of beer;).
    Jim.
     
    Last edited: Oct 1, 2017
    madmax-im, Boog, GeorgeOC and 2 others like this.
  13. Jim

    Jim Beyond the edge, is the unknown. Here be Dragons XS650.com Supporter Top Contributor

    Went to disassemble the head yesterday and couldn't find a valve spring compressor to fit the XS head. I know I had one at one time... musta' loaned it out and forgot about it. Damnit! Gotta quit doin' that. So... not wanting to hunt all over town or wait for one shipped to me, I decided to make one out of this...
    IMG_20171009_160704968.jpg
    I'm a pack rat. Too many of these buckets laying around.
    I cut and slotted two 3/4" tubes and welded them to a 1/4 by 1" flat bar.
    IMG_20171006_163320520_HDR.jpg
    Welded the nut for an acme screw (no idea where it came from, an old saw I think) on one end.
    IMG_20171005_195643658.jpg
    Cut the rubber handle off the screw and welded a T handle on.
    IMG_20171007_160009125.jpg
    Welded a 1/4" drill bit to the other end and cut it off at 1"
    . IMG_20171006_173715953.jpg
    Found a tube that was the same size as the valve springs and welded on three 1/16" allen wrenches. Cut them off at about 1/2".
    IMG_20171006_143831458_HDR.jpg
    Cut the sides out of the tube.
    IMG_20171006_164710772.jpg
    Welded the washer from the acme screw on top.
    IMG_20171007_154152867.jpg
    Drilled a wooden dowel to fit the other end, cleaned it all up and painted it and this is what I ended up with.
    IMG_20171007_162432325.jpg
    Worked perfectly!
    IMG_20171007_162242021.jpg
    Took about 2 hrs to make. It would have been easier to just order one, but I enjoy any chance I get to fire up the ol' TIG welder. Since I'm retired, I don't worry about the time spent, but that means I'm on a fixed budget. So, for a total cost of $0.00, I'm tickled pink.

    The bad news is that once I got the valves out, I found some pitting on both exhaust valve faces. Crap:(
    Jim.
     
  14. 5twins

    5twins XS650 Guru Top Contributor

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    That's pretty common. Usually you can just hand lap them back in. That will get rid of the pits and re-seal them. I've done some pretty badly pitted ones and so far, the seats have never grown too wide.
     
    Jim likes this.
  15. Jim

    Jim Beyond the edge, is the unknown. Here be Dragons XS650.com Supporter Top Contributor

    They might lap back in, but I'm leanin' towards re-cutting the faces. Haven't decided yet.
    Jim.
     
  16. Mailman

    Mailman Hardly a Guru Top Contributor

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  17. Jim

    Jim Beyond the edge, is the unknown. Here be Dragons XS650.com Supporter Top Contributor

    Thanks Bob. Pretty interesting tools in that link.
    Jim.
     
  18. Jim

    Jim Beyond the edge, is the unknown. Here be Dragons XS650.com Supporter Top Contributor

    My homemade valve grinder.
    IMG_20171009_210021852.jpg IMG_20171009_210021852.jpg IMG_20171009_210040534.jpg IMG_20171009_210013347.jpg
    It's a 1940 Atlas lathe that I brought back to life a few years back.
    I welded an angle and tube to a quick change block. Inserted a straight die grinder and clamped in place. Set the tool rest to 45 deg. and she cuts beautifully!
    Only took one light pass to remove pits on exhaust valves.
    IMG_20171009_210302006.jpg
    Tomorrow I'll lap the valves in and see how good it actually is.
    Jim.
     

    Attached Files:

    Last edited: Jan 31, 2018
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  19. Jim

    Jim Beyond the edge, is the unknown. Here be Dragons XS650.com Supporter Top Contributor

    Yeah, a good lathe is one of those tools that after using it for a while, you wonder how you ever got along without it. Just read your comment about your homemade tool height gauge. Good idea! Gonna make me one. Thanks 2M:)
    Jim.
     
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