S90: Fifteen Year-Old Rust

Not exactly sure what this is.  I think it's a mix of old gas and rust.  I literally had to shake it out of the original tank.

S90: Grips Installed

Pair of new grips arrived this week.  For some reason I thought these would be a real hassle to get installed.  Turned out to be a snap; had them both on within minutes.

Tools: Sanding Disc

This little contraption worked better than I'd expected actually.  You can bend the yellow plastic holder to navigate curves and bumps.

S90: Handlebars Coming Together

Put in a nice long session today full of odd jobs, but mostly centered around getting the headlight and handlebars back together after waiting on new parts, painting, and cleaning.

The newly painted plastic headlight case goes back into place.  Painting this piece was more an excuse to start figuring our my rattle can techniques than a serious painting effort. 

Next the headlight assembly and speedo go back in.  You'll note the rough edge at the bottom of the speedo's chrome part.  Normally you'd crimp that back into place but I purposefully left it that way so that it would be easy to take apart again if I need to.  I'm not 100% sure that all the fixes are complete to it, so I figured I'd leave it easy-to-open until I'm sure it won't need to come apart again.

The switches go back on, both with new levers (the old left side was bent, the old right was broken at the tip).  New throttle and brake cable.  New cable adjusters.

Unfortunately, the throttle holder on the new cable didn't quite fit the dimensions of these handlebars, so I switched it out with the original one.  This is a shot of the old one, which was just a tad too small.

S90: Speedo Update 2

Here's a shot of the speedo all cleaned up and with black touch up paint around the 40mph mark.  Not quite a perfect match on paint, but better than the chipping.

S90: New Rear Winker Bracket

For whatever reason, the rear turn signal bracket is one of those hard-to-find parts that rarely pop up on eBay.  A Thai repro part costs about $80 shipped.  Found this used one for just $16.50 shipped and jumped all over it.  It's got surface rust, but nothing that can't be polished out.

 

Garage: Paint Box

This set-up seems like it should work reasonably well for the small pieces.