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Mailman’s XS2 a full on restoration

Discussion in 'The Garage' started by Mailman, Mar 1, 2018.

  1. 59Tebo

    59Tebo 59Tebo Top Contributor

    It reminds me of the car shows, where a restoration takes a year or more, and the results are as perfect a specimen as possible. Better than when it rolled off the line. Paint is perfect (no "orange peel"), everything is lined up perfectly... As my old mechanic used to say regarding front-end alignments: "the closer you get it to perfect, the longer it'll last". Ya done real good Bob. It'll last you a very long time, without having to do much more than simple maintenance, feeding, and dusting (like with a "Swiffer"). :bike: So start it already! The suspense is killing me! :popcorn:
    TwoManyXS1Bs, Jim, GLJ and 2 others like this.
  2. gggGary

    gggGary On the road of life I'm a speed bump. XS650.com Supporter Top Contributor

    A late reply to gas tank paint removal.
    Guess the pics pretty well cover it. The later tanks do have a more defined, raised/lowered petcock flange area making it easier. I might do one of the early tanks just to see, a thought is put on a petcock and run a magic marker around it to delineate the area to be de-painted. The knock off x-acto knives are a handy tool for this and other precision knife work. They come out several times a year.
    first and last pics are one I did on a scruffy "test" tank. Guess I'm OCD (sound familiar?) but if the petcock is off the tank, the paint goes.

    TwoManyXS1Bs, MrBultaco, Jim and 2 others like this.
  3. Mailman

    Mailman Hardly a Guru Top Contributor

    Thanks Tebo! This really has been a fun project for me, and I’ve sure learned a lot along the way.

    Thanks for the pics. As you can see on the bottom of that gold tank, and as you said, the petcock mounting area is rather flat and ill defined. I have to admit that I have a pretty strong reluctance to carve the paint up, down there. Not only would it be pretty hard to do, the clear coat is quite thick on this paint and it would leave a square edge where the cut is.
    When I cleaned out the mounting holes and tapped the threads, I went over all the places where I cut the paint with super glue to try and re seal the paint. Yesterday I also did the superglue treatment all around the gas cap where I had to grind the paint to re fit the gas cap hardware. If my tank gets messed up I know a guy in Wisconsin that has all these beautiful painted tins hanging on a wall! :D
    MaxPete, geedubya, Jim and 1 other person like this.
  4. gggGary

    gggGary On the road of life I'm a speed bump. XS650.com Supporter Top Contributor

    That Wisco SOB is an early parts bogart, don't you know?
    MaxPete, geedubya, Jim and 1 other person like this.
  5. I've been away for a couple of weeks Bob and Wow you've just about finished, the bike is looking spectacular, can't wait for the big day.:thumbsup::bike:.
    Jim and Mailman like this.
  6. gggGary

    gggGary On the road of life I'm a speed bump. XS650.com Supporter Top Contributor

    Bob for your viewing pleasure. (or open mouthed HORROR)
    After starting the first side with the knife I switched to a stone in the dremel for the rest of the project. I felt the knife was too likely to lift paint I didn't want lifted. This paint is about 5 years old and not thick as yours so prolly more brittle. I was kind of surprised that the stone did all the paint removal without clogging. I kept the dremel at low speed which allowed controlled paint removal but did little metal removal or scalloping. I always use new o-rings to install petcocks but have not sized one for the early petcocks. I haven't sealed the paint edges yet but that's next.The neck went better with the knife since it was easy to cut at the sharp edge. Pretty sure this is a 2 part "epoxy" primer, it is strongly bonded to the metal. Enjoy.
    Last edited: Mar 22, 2019
  7. WBacon

    WBacon XS650 Member

    Well, I finally got through all this to the current posting. A real treasure full of information for an xs2 owner. Thank you Mailman, like everyone, I can't wait for your total success with this project.
    Wulfbyte, TwoManyXS1Bs, Jim and 3 others like this.
  8. Mailman

    Mailman Hardly a Guru Top Contributor

    Thanks Meddy! And welcome back, I look forward to seeing more rides from you!

    Mr. Bacon,
    Thank you much! You managed to slog through 122 pages and. 2423 posts! You are to be congratulated for your perseverance! I’ve wondered how many people would be willing to take that on! Haha :D
    Good luck with YOUR build, I hope you enjoy the process as much as I have.
    geedubya, Wulfbyte, Meddy and 3 others like this.
  9. Mailman

    Mailman Hardly a Guru Top Contributor

    I am not home right now, but check back. I want to have a detailed response and some questions for you as well! Thanks Bob
    MaxPete, gggGary and Jim like this.
  10. Mailman

    Mailman Hardly a Guru Top Contributor

    Edit: I removed my original post here, I was in a very down mood. My work was stopped because of some sudden medical issues. I permanently lost some vision in my left eye , it was feared that a brain tumor could be the cause and I was facing a whole bunch of medical tests and an MRI of my brain. In the end it turned out to be glaucoma, which I will be treating for the rest of my life. Anyways, this is what paused my work.
    Last edited: Sep 19, 2020
    MaxPete, gggGary, MrBultaco and 3 others like this.
  11. GLJ

    GLJ Never go faster than your guardian angle can fly. Top Contributor

    This is sadder than when you had to stop for your house move. Sincerely hope everything works out OK. I do believe the Mailman will be back better than ever.:thumbsup:
    Wulfbyte, MaxPete, JAX71224 and 4 others like this.
  12. Jim

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

    :lmao: Good idea. I brought up my feet in the SG thread and it turned into 4-5 pages of health related stuff. Not that I'm complainin'...:rolleyes:

    Go get your overhaul buddy. You'll be better than new. :D
    geedubya, Wulfbyte, GLJ and 4 others like this.
  13. member28833

    member28833 Race the wind Top Contributor

    We will be graciously waiting Bob, Your health matters the most !
    Get tuned up!
    GLJ, 2XSive, MaxPete and 4 others like this.
  14. Superjet

    Superjet XS650 Guru Top Contributor

    Get well mailman. I am doing the same been away from my garage for 3 weeks due to a buldging disc. Gonna be another 3 weeks or so before I can do anything on my bikes. Really bummed about it. Take care! JC
    GLJ, Mailman, gggGary and 1 other person like this.
  15. kshansen

    kshansen XS650 Guru Top Contributor

    Looks like we need to edit the title of this thread for some time:

    mail man.png

    If the Doc's do as detailed work as Mailman he should come back better than new!
    geedubya, Wulfbyte, GLJ and 5 others like this.
  16. azman857

    azman857 '80 XS 650SG Rider XS650.com Supporter Top Contributor

    Rule #1. Take care of self. We'll wait and send you waves of good stuff. Take care.
    geedubya, GLJ, MaxPete and 4 others like this.
  17. Scripto VU

    Scripto VU Dukes Speed and Custom

    Bob, during your house arrest
    I (we) hope your recovery is a relaxing and restful one. All the best and we hope
    we hear from you and your bike soon.

    (one of my personal mantras may work for you too)
    geedubya, kshansen, GLJ and 3 others like this.
  18. Mailman

    Mailman Hardly a Guru Top Contributor

    Thanks for all the encouragement and positive waves guys.! ( great movie by the way! ) I appreciate the support. I’m not going anywhere, I’ll be back at it as soon as I can!
  19. MaxPete

    MaxPete Lucille, Betty, Demi & Gretel: I ask, THEY decide. XS650.com Supporter Top Contributor

    We’ll be waitin’ for ya Bob.

    GLJ, Jim and Mailman like this.
  20. willis

    willis xsive compulsive disorder XS650.com Supporter Top Contributor

    Alright Bob, you take care of yourself. Just like your bike, we’ll be waiting here for your return. Godspeed brother!
    GLJ, MaxPete, Jim and 1 other person like this.

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