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Discussion Starter #24
A few people have asked about the decals that I created. I have attached a PDF with all of the graphics sized correctly. Please note that the background is pink and should not be printed :D Also, please note that these graphics assume that you are painting all of the stripes. Honda used a decal for the dark blue stripe.

For the record, I created all of these graphics from scratch and am not aware of any rules being broken. If I am breaking a rule, please let me know!

View attachment xrv650_rd03_decals.pdf

I've also been asked about upgrading the headlights to H4 bulbs. Here's how its done:
  1. Contact Jim Davis at Easter Beaver and ask for a kit to convert to H4 bulbs. Jim will sell you a new harness for the headlights. Top quality stuff and not expensive at all. Jim is a real asset to the Africa Twin community (he owns an RD03 and lives in Japan).
  2. Find new reflectors from an RD04, RD07 or RD07a. You will need these because the H4 bulbs won't fit in the original RD03 reflectors.
  3. Mount everything on the bike and enjoy more visibility at night!
 

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Ujenimotors

Cool!
 

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You and I are in a very small club: RD03 owners of North America! I count yours, one in Alaska, one in New Jersey and another in Canada.

Repairing plastic isn't too hard. I use fiberglass or fiberglass resin alone for holes and significant cracks. Sand away the excess resin and then apply bondo to smooth out the surface. When it comes to bondo (a bad word in some restorer's minds) there are two types. Normal bondo works great on tanks and plastic parts that won't flex at all. It is pink. "Bumper bondo" or flexible bondo is what I used on parts that I knew would flex a bit. Here's an example...

The disk guard had a large scrape and hole in it when I got it. I carefully fiber glassed the back of the hole and then filled in the front of the hole with flexible bondo. After a bunch of sanding and a few more applications of the bondo, the surface was perfect and ready for paint.

There are plastic welding products out there, but I haven't had experience with them.

Feel free to PM me and we can exchange contact info. Us RD03 owners need to stay in contact! :thumbup:



Fantastic work! Your project has provided me some much needed incentive! Sidetracked with too many projects lately.... I may PM you with some questions as well if you don't mind.
Cheers
Murray
 

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Discussion Starter #29
Hi Murray!

You have a great looking machine there already! I've followed your thread, so it will be fun to see you complete your rd03. To my knowledge, you have the only rd03 in Canada. Are you aware of any others?

Very happy to help of course. Pm me anytime!
 

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Discussion Starter #30
I'm in the final stages of getting the RD03 ready for its first bike show next month. Lots of little details to get right!

One of the major things missing was the original Honda plastic headlight guard. From what I have been able to learn, Honda offered the headlight guard as an accessory. Many were easily broken over the years, so they are exceedingly rare these days. If you have one, keep it safe!

As for me, I didn't have one...so I set out to make one. I created the guard as closely as I could for 3d printing:



I printed out a few test runs and was happy with the results when I came across an original guard on eBay in Switzerland. Wahoo! As cool as a 3d printed headlight guard would have been, I am happy to have found an original in great shape:



My next task is to fabricate the foam covers for the instrument cluster (mine were rotted and Honda no longer makes them). Stay tuned!
 

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. Many were easily broken over the years, so they are exceedingly rare these days. If you have one, keep it safe!
mine is safely stored on the front of the bike :)

they are quite a soft plastic, you did well finding an original :thumbup:
 

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Discussion Starter #33
Did you get radiator guards?

It isn't official without those. :p
Ha! In fact, I welded mine back together and repainted them!

Here's my first shot at new foam for the instrument cluster:



I started with a gym mat, cut it to the correct thickness, traced the pattern onto the foam, cut out the shape with a razor blade and sanded the foam down to smooth everything out. I'm pleased!
 

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Great stuff
 

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SEND PICS TO Mr HONDA TO REMIND HIM WHAT A REAL A/T LOOKS LIKE. CAN YOU IMAGINE THE SENSATION IF THIS TURNED UP FOR THE VERY FIRST TIME? OR, DARE I SAY IT, RESURRECTED IN MODERN FORM WITH TRADITIONAL LOOKS? DROOOOOL ! COOOOOL !
 

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Discussion Starter #38
Made it to the show!

To be more specific, it was the Quail Motorcycle Gathering in Carmel CA. Beautiful day and a beautiful event. I, of course, had the only two Africa Twins on display. Got a lot of questions and interest in the bikes. No awards (6-digit bikes win at this kind of show!). I joked that I won "Best Africa Twin of Show" and runner up :toothy10:

The RD03 looking near-new:



To educate those who had no knowledge of the Africa Twin, I created a timeline and had it printed out as a billboard. Here it is:



And a pic of me with my bikes:



Its been fun getting this bike into this condition.

Now to ride the piss out of it! :blob7:
 

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You should be proud of yourself

Well done on 1st and runner up too! (in your category)
 
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