The frigid season is truly upon us here in Central New York State, so its time to get wrenching full time.
The first of the bikes to be wheeled into the warm winter workroom is my '73 Yamaha DT3 Enduro "backyard bike".
I replaced the seals in the lower fork tubes last winter, but one of them leaked badly, apparently due to the significant pitting of the upper tubes.
The rusting in the pits is pretty deep, so the usual methods might not be effective. I decided to fill the pits with some sort of compound. I have read that some folks fill them with bondo, but I decided upon my favorite, JB Weld.
Here is an example of what I'm dealing with:
First I used a sharp ice pick to dig out the rust down to clean metal.
Then I cleaned the pits with rubbing alcohol, followed by a burnishing with a small wire wheel dremel attachment.
Alcohol cleaning again.
Applied naval jelly, soaked for 30 minutes. Alcohol cleaning again.
Then I went outside for some fresh air.
After drying thoroughly, I used a razor blade to putty in the JB Weld:
12 hours later, I sanded the excess epoxy first with 800 Wet-or-dry sandpaper using WD 40 (so as to not introduce water), followed by 1200 grit.
It sanded down quickly and easily.
When I was done, with eyes closed I ran my fingers across the pits. The surface was completely smooth.
The shine of the chrome was slightly dulled, and the discoloration of the pits were evident, but heck, its just a backyard bike, and besides, I installed some gaiters to protect the tubes.
Truck gaiters by Daystar, as recommended by 5Twins.
I'll take them apart next winter to check the status of the repair, and I'll report back the results.
.
.
.
The first of the bikes to be wheeled into the warm winter workroom is my '73 Yamaha DT3 Enduro "backyard bike".
I replaced the seals in the lower fork tubes last winter, but one of them leaked badly, apparently due to the significant pitting of the upper tubes.
The rusting in the pits is pretty deep, so the usual methods might not be effective. I decided to fill the pits with some sort of compound. I have read that some folks fill them with bondo, but I decided upon my favorite, JB Weld.
Here is an example of what I'm dealing with:
First I used a sharp ice pick to dig out the rust down to clean metal.
Then I cleaned the pits with rubbing alcohol, followed by a burnishing with a small wire wheel dremel attachment.
Alcohol cleaning again.
Applied naval jelly, soaked for 30 minutes. Alcohol cleaning again.
Then I went outside for some fresh air.
After drying thoroughly, I used a razor blade to putty in the JB Weld:
12 hours later, I sanded the excess epoxy first with 800 Wet-or-dry sandpaper using WD 40 (so as to not introduce water), followed by 1200 grit.
It sanded down quickly and easily.
When I was done, with eyes closed I ran my fingers across the pits. The surface was completely smooth.
The shine of the chrome was slightly dulled, and the discoloration of the pits were evident, but heck, its just a backyard bike, and besides, I installed some gaiters to protect the tubes.
Truck gaiters by Daystar, as recommended by 5Twins.
I'll take them apart next winter to check the status of the repair, and I'll report back the results.
.
.
.
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