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Thread: Make Alp Great Again Rebuild Project

  1. #21
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    Re: Make Alp Great Again Rebuild Project

    So pretty calm day compared to yesterday's madness. More cleaning and rust removal. Made a comprehensive parts list which took some time. 7 Bearings for the whole rear suspension is a bit of a shocker , 25 euros a piece OEM. Sending the list to a Kiwi fella who might be able to source some parts in New Zealand or Australia. Otherwise most parts will have to come from Europe.

    The rear rim suffers from the typical Transalp Corrosion. I've been trying to find some info on fixing them up but most people end up opting for replacement. The rear rim has been corroded on the outside ever since I got the bike and the wheel has taken some serious abuse ever since without breaking in half. Does anyone know a thing about filling the corrosion with Alumaloy?



    The guy in this thread used it but he opted for a replacement in the end (thanks to him I'm staying far away from the spokes).

    On a different note I think there might be something stuck on my eyeball.

    Last edited by alpoverland; 05-01-17 at 06:58 AM.

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  3. #22
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    Re: Make Alp Great Again Rebuild Project

    Try looking for pattern bearings - Here in the UK from bearing specialist distributors they can be half/third the cost of OEM.

    Any chance for you to locate a donor Transalp down under (NZ / Aus) that's breaking? that could provide much needed parts for MAGA. Keep up the vids and looking forward to seeing more of your rerfurb and rebuilding of the T-34/600

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    Re: Make Alp Great Again Rebuild Project

    +1 on using off the shelf bearings, they are much cheaper and you can still choose what you want, I.e nsk, koyo, fag etc

    You will find a bearing shop in most cities throughout the world!

    You just need the dimensions or the originals that want replacing

    The same goes for most seals!

    I know from experience the alp has a few sneaky bearings that can only be bought from Honda unfortunately
    Last edited by jamie92j; 05-01-17 at 06:03 PM.
    everything is OK

    Central Asia 2014

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  6. #24
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    Re: Make Alp Great Again Rebuild Project

    Quote Originally Posted by Wicky View Post
    Try looking for pattern bearings - Here in the UK from bearing specialist distributors they can be half/third the cost of OEM.

    Any chance for you to locate a donor Transalp down under (NZ / Aus) that's breaking? that could provide much needed parts for MAGA. Keep up the vids and looking forward to seeing more of your rerfurb and rebuilding of the T-34/600
    Thanks mate. I'll be going aftermarket for the steering and wheels. Figured for something tucked away like the suspension go OEM but I have repeatedly heard that aftermarket bearings does not mean less quality. So definitely aftermarket but as Jamie below says: sneaky bearings. Jorge here mentioned the same thing. As for donor bike if I wasn't going for the AT mod then that would be a good option. And then with the blessing of the motor gods find out the bike comes with all the parts needed for the AT mod like that lucky bastard Danjet.

    Quote Originally Posted by jamie92j View Post
    +1 on using off the shelf bearings, they are much cheaper and you can still choose what you want, I.e nsk, koyo, fag etc

    You will find a bearing shop in most cities throughout the world!

    You just need the dimensions or the originals that want replacing

    The same goes for most seals!

    I know from experience the alp has a few sneaky bearings that can only be bought from Honda unfortunately
    Yeah invercargill is like the South Island farming capital so good chance of finding bearings here. I'll be looking online too. Any suggestions for aftermarket bearing brands? Jorge suspects that the needle bearings might be one of those sneaky Honda parts. Fingers crossed.


    Allright, it happened, with the power of the AXE! Finally slammed that remaining piece of axle out. Cheeky bugger. Cut the rod short so I could hit it harder and kept waking at it with the axe. Combined with crc baths the bloody thing finally started to give until it flew across the garage. Good thing I moved the camera before that. Really happy about that. Felt frustrating removing rust on the frame knowing it still had to be washed and degreased properly so everything would just rust again.

    Slow day after today. Only went to Invercargill to buy more supplies. Also a doctor removed that tiny piece of metal from my eye so happy days. Also bought a tube and baking soda to try and make a soda blaster.

    Does anyone know more about painting the Transalp? Do primer, paint and clearcoat or use a primer/paint in one? People tell recommend me different things now. Tough time figuring out the right color of original silver. Online I found the following reference:

    Rustoleum Professional High Performance Enamel Aluminum 7515838

    Would like to know to what paint color code that translates to. As for the frame I'm starting to seriously consider powder coating. It would be great if there were like simple vector designs of motorcycles in digital image form so you can play around with the color scheme. Realized I need to think more about the paint job and do more research. Almost bought primer today to start on that tomorrow but then someone mentioned there might be compatibility issues with certain paints later on. Leaning towards a more traditional color scheme but for example I love what KTM does with the orange frame. But also, how much do I want my bike to stand out in South and Central America. I don't really worry about those things but I am realistic. Maybe leave the popping colors until the potential phase two of the build in the States. The whole paint part of the project is raising more answers than questions so something to think about during the part waiting period when I go back to work.


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    Re: Make Alp Great Again Rebuild Project

    Good you got metal out your eye! How on earth did it get there as I noticed in your vids you've been diligent in wearing protection. Plus very satisfyiing to get that other irritating bit of metal connecting the frame to the swingarm!

    Paintwise - like you've been doing remove all rust. If you go the power coating route they should have access to grit blasters to key it all up before coating - though grit can enter the frame / hollw areas and if not throughly cleaned out can later down the line bugger bearings . If you go to paint it yourself then you'll probably need etch primer which is pretty toxic stuff to spray in large quantities and would need a forced air supply special respirator to apply not just a dust mask.

    Some paint you can slap on - but all depends on the instructions on what you can readily lay your hands on.

    POR15 Rust Preventive Paint, High Temp Top Coat and Primer | Frost Restoration


    As for colour - any colour apart from white!!

    You may remember me writing a short while ago about the sad situation the two motorcycle overlanders had ended up in in Rio.
    My friend Mike, who first let me know about this, has now arrived in Rio himself and has sent me an update. Mike says:

    'Hi Sam. I now have some background info on the two unfortunate chaps in the Morro Favela in Rio. The local military police "Choque" [Shock] units use adventure type bikes [often white painted locally made Honda 400 Falcons] and wear high vis waistcoats, over european type riding gear and boots. The two Italian chaps were running waze gps app, downloaded to smartphones and had helmet camera's. Hence they were mistaken for two police riders. The area they strayed into has drug dealer spotters on every entrance/junction, almost certainly all armed. A case of two chaps, looking like police, riding police like bikes, hence the spotters would shoot immediately. I guess the message is, don't look like police and take local advice when travelling these areas. If it starts to look rough, turn around and ride straight out.'
    What a sad story eh. Such an easy thing to have happened
    I also mentioned the farm that to quote Mike, is a place 'where overlanders are welcome to chill out and recharge for a few days'
    It's just north of Rio (couple of hours). The co ordinates are 21°58'25.63"S - 43°11'4.62"W


    https://www.facebook.com/search/top/...anicom%20posts

    Last edited by Wicky; 06-01-17 at 08:59 AM.

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    Re: Make Alp Great Again Rebuild Project

    Nice work man. Like Wicky says, paint and powdercoating both have their pro's and con's. I also dubbed between paint and powdercoating, but I opted for the powdercoating for my frame, even if it is the more expensive choice. If you paint you're frame, it's never to be painted as good as Honda did in the factory. It'll get easely damaged by stones and stuff and then it will probably going to rust again. On the other hand, if something is rusting you can easely spot it. So, if you would paint the frame, I would recommend it being done by a professional company which use proper paint.

    A powdercoated frame can still rust beneath the coating and when you can finally see it, it's way too late. But if it has been grit blasted correctly, there won't be any rust for decades. Also, powdercoating is very hard and won't get damaged easely. I would recommend to buy some tectyl ML and spray it in open cavities of the frame to make sure it won't rust out from the inside.

    Painting it you're self is by far the cheapest option which is good for a tight budget, but will cost you lots of time prepping the frame. Powdercoating a frame with some bits and bobs cost me around €150 and you don't have the hassle of grinding down and painting the whole frame.

    I'm following this closely, nice to see you're bike gets a good treatment during your'e awesome trip!

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  11. #27
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    Re: Make Alp Great Again Rebuild Project

    Quote Originally Posted by Wicky View Post
    Good you got metal out your eye! How on earth did it get there as I noticed in your vids you've been diligent in wearing protection. Plus very satisfyiing to get that other irritating bit of metal connecting the frame to the swingarm!

    Paintwise - like you've been doing remove all rust. If you go the power coating route they should have access to grit blasters to key it all up before coating - though grit can enter the frame / hollw areas and if not throughly cleaned out can later down the line bugger bearings . If you go to paint it yourself then you'll probably need etch primer which is pretty toxic stuff to spray in large quantities and would need a forced air supply special respirator to apply not just a dust mask.

    Some paint you can slap on - but all depends on the instructions on what you can readily lay your hands on.

    POR15 Rust Preventive Paint, High Temp Top Coat and Primer | Frost Restoration


    As for colour - any colour apart from white!!
    A ricochet probably somehow. I've done quite a bit of demolition work in the past and nothing like that happened. Except once while removing a glass panel and looking up, something fell past the glasses (no glass luckily). I do wire wheel at full speed and wire bits fling of constantly. Yesterday a fella at supercheap said to wire wheel on slow that way the bit will last longer. Pretty frustrating speed but I'll give it a go. Thanks for the info mate. There really are pro and cons to either processes.

    Quote Originally Posted by Turbinerepair View Post
    Nice work man. Like Wicky says, paint and powdercoating both have their pro's and con's. I also dubbed between paint and powdercoating, but I opted for the powdercoating for my frame, even if it is the more expensive choice. If you paint you're frame, it's never to be painted as good as Honda did in the factory. It'll get easely damaged by stones and stuff and then it will probably going to rust again. On the other hand, if something is rusting you can easely spot it. So, if you would paint the frame, I would recommend it being done by a professional company which use proper paint.

    A powdercoated frame can still rust beneath the coating and when you can finally see it, it's way too late. But if it has been grit blasted correctly, there won't be any rust for decades. Also, powdercoating is very hard and won't get damaged easely. I would recommend to buy some tectyl ML and spray it in open cavities of the frame to make sure it won't rust out from the inside.

    Painting it you're self is by far the cheapest option which is good for a tight budget, but will cost you lots of time prepping the frame. Powdercoating a frame with some bits and bobs cost me around €150 and you don't have the hassle of grinding down and painting the whole frame.

    I'm following this closely, nice to see you're bike gets a good treatment during your'e awesome trip!
    Bedankt voor de info maat! I'll be contacting the powdercoat place out here to check out pricing and to find out how they prep the frame. For now I won't start removing rust on the frame although it is tempting to start having a go at those many eye sore spots. Swingarm will do for now. Cheers for that, though I must confess that for the last 5 years the bike has gotten an awful maintenance treatment and it does not help that the Transalp can handle that so well. Damn you Honda you and your superior build quality! That being said though, this is one lucky bike. The stories she tells the other bikes!

    Damn I haven't done anything this morning yet. Just browsing, must stop. Looking at the AT mod situation. So I stumbled on rally fairings again and due to the pricey nature of the front side fairings and front cowl + screen they are an economical option and in mint condition.

    So these guys are almost on the money with the windscreen option except for the round design of the side fairings. Forgive me TA650 crowd for saying this but I'm not a fan of the round design. RD04/03 design just looks perfect with those hard corners. same for the TA600. Will it fit with an RD04 tank? Would have to contact them.

    Perfect Fairings - RALLY FAIRINGS - Africa Twin RD07 Rally fairing OEM look

    This one though is on the money but then it fails in a different department and that is no windscreen. Apart from the rd04 windscreen looking great I really enjoy having a windscreen. You sit out of the wind meaning less strain on the body during the daily ride and you don't get really wet during mild rain. Original rd04 front just looks amazing.

    Perfect Fairings - RALLY FAIRINGS - Africa Twin RD03 RD04 rally fairing

    EDIT: Dit not see this one at first. Good potential fail safe though I wonder if the non-see through screen blocks the view. Still.

    Perfect Fairings - STREET FAIRINGS - AFRICA TWIN 650/750 RD03 RD04 FRONT FAIRINGS

    And then there is the Rugged Roads rally fairing which, again forgive me, has become affordable due to the monetary blessing of Brexit. Less round on the sides and looks like quality stuff. Would have to get their smaller headlights but again low British pound and secondhand rd04 headlights are a similar price. We would have to create a mounting system for the front though.

    Africa Twin Fairing RD03/RD04 - Rally Light - Rugged Roads

    All these choices. My parents never prepared me enough for life's tribulations. Meanwhile my wallet gently weeps waiting for the massacre to come. Does anyone know any other options out there or has experience with the before mentioned fairings?
    Last edited by alpoverland; 06-01-17 at 11:43 PM.

  12. #28
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    Re: Make Alp Great Again Rebuild Project

    Easy day mostly spent removing rust from the swingarm with took some time. Started using the slower setting on the drill for the wire wheel which turned out to be a pretty good idea. Had another birthday bbq so no work in the evening.

    AT rally fearing is really starting to grow on me but only the complete kit comes with the console panel and a headlight frame. That price though, not even Brexit can save me there.

    Africa Twin Fairing RD03/RD04 - Rally Light - Complete Kit - Rugged Roads




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    Last edited by alpoverland; 08-01-17 at 12:49 AM.

  13. #29
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    Re: Make Alp Great Again Rebuild Project

    First stint down in Tuatapere is over and I'm back to work in Cromwell. On the last day we, Jorge, finally dug into the engine to see what is going. Plenty of burnt residu on the pistons and the valves. The bore was looking alright and there were minor scratches on one side of both the pistons. We took the lot to Honda for them to do the measurements.

    Meanwhile they have gotten back to me. Front bore .07 (under), front bore .11 (over). They will have to be rebored, new pistons, rings and exhaust valves. The inlet valves can be cut and reused apparently. I don't know yet what that means. Glad to have the final verdict on the engine.

    So back to work and this week parts will be ordered. Three weeks to get it all. Then back to rebuild Alp. Madness.



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    Re: Make Alp Great Again Rebuild Project

    Mooie update weer . Good to know what ur up to now. Btw, how's the output schaft?

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