Xl 600 LMF rebuild by Andrew W

[andreww5680]

I have stripped the frame down and sent it for powdercoating. Unfortunately the bloke doing it sandblasted my id plate on the side of the frame which i specifically asked him to mask off- i even suggested id take it off but he said leave it to the pros - arsehole


I have bought astandard headlight fairing untill i do something with my fairing which is a little worse for wear- (see my gallery)

[andreww5680]

my current progress (apart from stripping the bike) is

Clean and polish front wheel and forks, remove mudguard and wet and dry mudguard ( badly scratched) - this has come up really good (pics will follow)
Sandblast and respray the silver plate above the mudguard.
Assorted blasting and repainting (mainly black components) see pics below.
Frame powdercoated and resprayed- awaiting return (poss tomorrow) after spray shop f up (any ideas for a replacement plate ??)
Some bolts sent off for plating- awaiting return
refit clocks to new bracket (thieves broke old one)
engine side covers blasted +barell and head- awaiting paint (see pics)
Crankcases prepared by hand- when i get the side covers back etc i will reassemble the engine, mask off the painted areas and the crankcases will get resprayed.
Barell and head faced off to repair head gasket damage (see pic)

Please comment- your thoughts are much appreciated.




Before



after



BLasted engine






Crankcases 70% prepped (this paint is hard- took me weeks)



Parts already painted

[andreww5680]

for other pics of the build please see my gallery--- andreww

[stubbow]

Looking good mate
Only thing i noticed is the headlight cowl is not an lmf, its the same as the one that i have for mine, for it to fit you will need xl600r headlight brackets and the 600r lower cowl mount(it doesn't fit with the silver bracket as the cowling is longer)

I need the two side panel decals if you are having some made up maybe you could get an extra pair for me

Danny

[andreww5680]

Hey Danny

I have asked the sticker guy to quote me for the paris dakar side cover stickers (like yours should be) and the e- start (like mine should be). Hopefullly hear tomorrow.

I should get the frame back tomorrow and poss drop the engine in- im a bit fed up with the paint guy as he is taking his sweet time. Ridiculous- 3 weeks to paint a frame. I got my exhaust painted and a fw more of the aftermarket fairing brackets (when i manage to get a screen i would like to swap the fairings over again) RE: the temporary screen- enduro man said it would fit- i will have to investigate. I have the brackets- they are getting painted today so shouldnt be a prob.

Andrew

[stubbow]

Great thanks for that
If you have the correct brackets the shroud will fit fine.
Got my motor in today, a little tip wrap the frame tubes in bubble wrap as its a struggle to get in and its easy to scratch the frame.
Danny

Hey Danny

I have asked the sticker guy to quote me for the paris dakar side cover stickers (like yours should be) and the e- start (like mine should be). Hopefullly hear tomorrow.

I should get the frame back tomorrow and poss drop the engine in- im a bit fed up with the paint guy as he is taking his sweet time. Ridiculous- 3 weeks to paint a frame. I got my exhaust painted and a fw more of the aftermarket fairing brackets (when i manage to get a screen i would like to swap the fairings over again) RE: the temporary screen- enduro man said it would fit- i will have to investigate. I have the brackets- they are getting painted today so shouldnt be a prob.

Andrew

[andreww5680]

Nice one Danny- i was planning on taping rags all over the frame when i get to that stage. I even raided a skip the other day for some decent size cushions that i can use as a work area so as not to scratch anything.

Your engine looks mint from the pic if i had of known i may not have gone down the blasting route and could have prepped and sprayed by now. I have done a little more crankcase work today- it is coming along nicely. When my barell and side covers come back from paint i plan to reassemble and mask off the painted areas- all the sprayer has to do is the area in between - in theory !!

Spotted this :

Honda XR600 Stainless Engine Bolt Kit on eBay, also Honda, Motorcycle Parts, Motorcycle Parts Accessories, Vehicle Parts Accessories (end time 10-Jul-09 17:43:03 BST)

Maybe i should buy it- i do still plan on getting the originals plated- although stainless is the long term solution. I think it should be compatible as the xr has a very similar lump.

I rebuilt my exhaust today- it is an aftermarket unit but now it has been blasted and resprayed looks half descent prob is quite a bit of rust so i didnt go too heavy on the preping and it should hold well under the paint- want to keep my eye out for an original muffler. The downpipes look ace- where i did all my blasting is a local engineering company that i deal with at work and not only did i get to use their blaster FOC but he even took my downpipes and got them painted at an industrial exhast manufacturer
who are also good customers of theirs !!!

Main problem i have is getting my fasteners back from the platers- if they come back i can get on with some work- another favour so cant really push too hard if you know what i mean.

[andreww5680]

Thought id put these in- this is my evenings progress

First pic shows the exhaust system including collets. The downpipes were sprayed at a silencer manufacturer in heat resistant paint and the muffler was powdercoated (at work ) I had to repair the first mounting bracket whicd i did (as in pic) Had to leave some surface distortion due to rust but surface still blasted

[Kjell Lindberg]

You are doing a fine job there!

I will follow the progress.

[andreww5680]

ok everyone here are some more pics of the newly painted frame and headlight bracket

Here is the unfortunate part:



No plate

Here is the bracket that goes below the headlight which looks mint



And finally this is the front mudguard. There were really deep scratches on the right hand side about 3 inches long but a day of sanding seems to have done wonders !!