Monster rustoration

[crust]

So onto the engine, or so I thought, after a bit of reading I pressed the button on some exactfit belts and to be safe some moving tensioner bearings.

Whilst taking off the belt covers I noticed oil residue behind the rear cylinder.




Now theres a dilema. It's not much but I don't like it. So head and barrel off to repalce base gasket?

Hmm, last time I did that I snapped a ring on the horizontal cylinder, then there's that set of 944 pistons and standard spare barrels on the shelf. Get the barrels rebored and plated to 944, not this month.

Ok, on to other parts then.

[crust]

Front wheel scrubbed within an inch of it's life - paint is blistering so that'll need a repaint at some time.

So disks then.

[crust]

That went well so time for the calipers:

[crust]

Lesson learnt when blowing pistons out with compressed air

1. One will always come out like a rocket, the other wont. Luckily I had my palm over the pistons, good job I didn't have a piano recital that night

2. Wear glasses because when the rocket takes off the residual brake fluid sprays all over the place.

3. Wrapping the caliper in an old towel prevents all this.

All came up very well and looking very nice inside. One small 30mm piston has a slight nick in it so may need replacing.

Wheel and calipers back on, just need to bleed them.

[slob]

can you tell if the oil coming from the base gasket or the breather valve?
one might be a lot less work to fix than the other ;-)

[crust]

Oh, good question.

Hadn't thought of that, will investigate.

no thumbs up smiley or like button

[Darren69]

What did you use on the calipers, just brake cleaner? They've come really well.

BTW These are great for getting the breather valve out, dead easy: -

https://www.ebay.co.uk/itm/Multitool...MAAOSwxR9d8ZGO

[utopia]

My memory's not always so good but this quote from 2011 stuck .....

" Fairy Liquid, very hot water and a stiff tooth brush.
Remove wheel, leave caliper dangling.
Fill bucket with hottest water you can stand, add plenty washing up liquid, scrub like buggery, keeping dunking in bucket. "

I'm guessing you used the same method this time.

It was the "scrub like buggery" which made me chuckle and set the memory tag.
I also remember being slightly miffed at the time because the forum censor allowed "buggery" but it wouldn't let me write "sn1gger".

[crust]

A slight variation on the theme this time as I knew I was going to properly flush the brake system and I wanted to split the calipers.

I took them off the bike, gave them an initial soak with SDOC and then attacked them with the hot soapy water and scrubbing brush. That got rid of the surface layer but not in the gap where the disk sits, so then I split the calipers, covered the halves in SDOC, scrubbed that off and left them to soak in very hot soapy water before giving them another good scrubbing with a stiff bristle brush.

Gave the pistons a polish with just a soft cloth until all the residue was gone, a thin coat of red rubber grease, pop them back in and re-assemble calipers.

But, yes, there was a lot of scrubbing like buggery to get all the baked on grime and brake dust off.

[Pedro]

Excellent work Simon! Nice to see the old girl out in daylight

If you’re painting the wheels, I found your cush drive rubbers puller in my tool box the other day, want me to post it back?

I still think chasing you up that italian pass on the way to WDW 2007 was the scariest ride of my life... lol!

[crust]

Cheers Pete

I'm definitely enjoying it and looking forward to getting out on it for a ride and catching up with folk.

The wheels will get repainted at some point, probably over the winter, along with a load of other parts.

Keep hold of the cush tool for the minute, it'll give me an excuse to meet up at some point

2007, wow, that long ago. Yup, the Migliatore is a phenominal road.

[Zimbo]

Nice to see it out Mr Crust, last saw it on a Mallory track day I think, enjoyed chasing it around the Scottish highlands as well 😄

[crust]

Next on the list - rust spots on the inside of the tank.

Brief sidetrack - I wanted to see more of the inside of the tank so spalshed out £9.99 on a Eurocarp parts endoscope. Don't, not sure you even get what you're paying for. The software supplied simply doesn't work. Tried a number of apps, a random USB camera one sort of did.

It showed a lot of the tank with these:



Someone had recommended DEOX - https://www.bilthamber.com/

So I ordered some DEOX and some Surfit degreaser. Washed the tank out with degreaser and then mixed up the DEOX and poured it in. Through the filler cap you could see a patch of the tank with a light coating of surface rust, the DEOX got rid of that just pouring it in

Left it for a couple of hours, swilling it around every 15 mins or so. The results are pretty impressive where the metal was submerged, slightly less so where it was only getting wetted when swilled as you'd expect.

Submerged



Swilled



Overall I'm happy there's no rust to wash off and block fuel filter or rust through the tank.

[crust]

Inside done I treated the tank to a new latch (the old one was held together with wire) even dug out some black bolts for the tank cap rather than the dog-eared chrome ones it had before.



Inside and top of tank done (some repainting to do on underside) it was back to the front end.
First up some shiny new Ti disk bolts – forgot to take picture – Doh!
Then on to replacing the horrible rusty bolts holding the caliper together:





Then an hour or so bleeding the brakes, from the top, bottom, pushing pistons in and out, still spongy but I got bored.

[crust]

A few little jobs like replacing the perished tank prop rubber:



Then fit the new belts



Refit belt covers. Smile and call it a day.

And yes, I've decided to 'forget' the oil weep for the time being as the motor may well be coming out in the near future for a refurb.

Next up - refit carbs, oil change and see if she runs. Work is going to get in the way for the next couple of weeks so it will be slow progress.