1980 Build for Dad

Rhy650

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Hello all, the purpose of this log is to chronicle the two projects that I outlined in this post regarding my late father. Once again, I would like to thank you all for the kind words, it means a lot to me to know that he was respected and will be missed by so many. He really was one of the most outstanding people I have ever known and certainly the most mechanically gifted. Let’s hope I can do him proud with this work.

A little about me… I am married and a father of three with an 8-month old baby girl and two boys, 5 and 8. I am a molecular biologist and manage a CAP/CLIA (accredited /state-certified) clinical genetics laboratory. I had the bright idea to start a COVID-19 testing program at the end of March, so between work and family I do not have as much free time as I would like for my tinkering. Please forgive me if these projects take a while to complete! This is also my first time really posting to a forum, so please let me know if there is anything I can do to improve the style/content of this thread.

I am choosing to finish the 1980 first, as this is my first time really working on an XS650 and if I am going to make mistakes I rather them be on this bike than Dad’s XS1. I have the bike running and even looking fairly good at present, but wanted to tackle an engine build. The engine in the bike now is an eyesore next to the freshly painted tank and is leaking oil from at least two seals. This bike came with an extra engine (and Dad has maybe another half dozen laying around…) so here we go...!

To date, I have completely torn down the engine and have done my best to “bag and tag” all of the pieces. My engine building experience prior to this consists of a 5hp B&S off my minibike when I was 12, so naturally I was horrified with the sheer number of pieces spread across the bench when I was finished.

This past weekend I was able to degrease the cases and make it over to a friend’s house to soda blast them. Great technique, I was very pleased with how they turned out. It was also one of the single messiest tasks I have ever engaged in. It was a decently warm day and I broke just enough of a sweat for the aerosolized soda to cake nicely onto my entire person…

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From here I pressure washed the pieces, taped off the internals, and wiped all surfaces to be painted with acetone.

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I applied a VHT high-temp primer then enamel per the manufacturer’s directions. Again, I was very pleased with how they turned out. Dad had previously made a collapsible paint booth from PVC that greatly improves the quality of aerosol can projects. I know there are better engine coatings out there, but this fit the bill for the scope of this project.

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I started assembly by reinserting the studs into the upper half of the case. It took a bit of guesswork and measuring to get the studs in the right order, but I eventually got it figured out. Dad had made his own stud puller which made the task fairly easy along with a 1/2" drive torque wrench.

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I am waiting on a new cam chain and other goodies to arrive before I install the crank. In the meantime I plan to continue my studies of the crankcase assembly. The shifting mechanism in particular I find very confusing... I might also start working on the heads, lapping valves, rockers, etc... Also need to look around for a shop to bore/hone the jugs for me as new pistons will be going in. Lots to do, will keep you all posted as to my progress!
 
Excellent! We are so happy you decided to stick around the forum, you are a most welcome new member. I can certainly see how divided your precious time must be for you. The work you are doing so far looks well thought out, your dad is smiling on you right about now. Keep up the good work, I am looking forward to following your progress.
There is a very good pool of knowledge here, so you’re in the right place. I’m sure you’ve discovered our tech section ( at the top of the page ) , but here is a really good top end build up thread from that section.

http://www.xs650.com/threads/xs650-top-end-buildup.52041/

Good luck to you and welcome aboard! :)
-Bob
 
Rhy, you have made a great start. Your approach is very meticulous and organised, so I am sure you will do a superb job on the bikes.

This is is a great project, building these bikes in honour of your recently and sadly lost father, Jake. I am sure you will have the full support and encouragement of everybody on this forum.

Edit - I crossed in the post with Mailman but endorse his sentiments
 
so please let me know if there is anything I can do to improve the style/content of this thread.
Larger pics? Us old farts don't see so good these days. :)
I think fixing the 80 first was a wise decision. If you haven't already bought 'em Cruzinimage will be your best bet for pistons and rings.
Looking forward to seeing this come together.
 
Once again welcome Rhy - it is great to see you continuing with your Dad's legacy and really nice to see what a craftsman you are.

Ask lots of questions, post lots of pictures and enjoy the gentle joshing that goes on - you are certainly among friends!

Pete
 
If I haven't said it already, WELCOME! Really liking what I see so far, I don't think you'll have any problems with the rebuild. As motorcycle engines go, the XS is one of the simplest and parts are everywhere.

I'd be interested in pictures of your Dad's PVC Paint booth if that's convenient at some point. I do quite a lot of aerosol/rattle can painting as well as airbrush work on my models. I have a paint booth of sorts that I re-purposed out of 3/4" MDF and it works well but its DAMN heavy and in the way all the time when I'm not using it. Something light and collapsible sounds like the perfect solution.
 
Something light and collapsible sounds like the perfect solution.

I've been thinking the same thing - a foldable wire frame about 30" high x 30" wide x 24" deep with a "skin" made out of heavy-duty vapour barrier with a vacuum cleaner sucking the air out of it might be just the ticket.....
 
a vacuum cleaner sucking the air out of it might be just the ticket.....
:yikes::yikes::yikes:
My ex once sucked a cockroach up in a vacuum cleaner. Wanting to make sure it was dead, she sprayed bug killer into it and blew it to kingdom come. I'm thinkin' spray bombs are called that for a reason. Let's don't be suckin' up them fumes. ;)
 
Welcome Rhy! Just want to echo what everyone else has already stated. Will be following this thread with interest. Was so impressed with your Dad's ingenuity, attention to detail, and machining skills. From the work you are doing, and as a molecular biologist, it is clear you are a chip off the ole block. Thank you for giving us a front row seat as you finish these builds in honor of your Dad, and thanks for your work in healthcare!
 
:yikes::yikes::yikes:
My ex once sucked a cockroach up in a vacuum cleaner. Wanting to make sure it was dead, she sprayed bug killer into it and blew it to kingdom come. I'm thinkin' spray bombs are called that for a reason. Let's don't be suckin' up them fumes. ;)

Awww....c'mon Jim - just tryin' to have a little fun...;)
 
Clean rooms always use positive pressure, just say'n.
Welcome to cat herding central Rhy650.

Positive pressure is really the way to go - but getting a supply of clean air to pump in is the problem - unless you have a handy hole in the wall.
 
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Automotive paint shops in OEM vehicle assembly plants all use air-locks and positive pressure to keep dust off the new paint jobs - and it takes a huge volume of air to do that for a 3 story floor area of 700,000 - 1.5 million square feet - and that costs a ton-o'dough. The air is simply exhausted to the atmosphere - and in some locales (like LA) with all the filtration on the incoming air, the outgoing is actually cleaner than the incoming even with the paint fumes.

In fact, a lot of the most modern OEM paint shops use a dry electrostatic paint process that release little or not volatile organic compounds (VOCs) and so the level of air pollution is minimal.
 
Just an idea, when I’m working on anything with fumes I want to evacuate, I set a high velocity fan somewhere in the back of the garage, blowing outside. Fresh air will be drawn in and circulate back out the door. Kinda like this.
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If you did a set up like this, along with using a quality 3 Stage Respirator, you should be good to go.
 
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