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Classic Bike Trackdays

RG125UN wolf restoration. (picture heavy)
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BenR



Joined: 24 Aug 2009
Posts: 59

PostPosted: Fri Dec 04, 2009 3:59 pm    Post subject: RG125UN wolf restoration. (picture heavy) Reply with quote

Hi My name's Ben. Here's my little restoration project I've been doing most of this year. Only a 125 but I love it. I had one originally brand new back in 1994 so decided to get another one, actually this is my fourth RG. Anyway time for some pics. Smile

When I picked it up back in March:




Unfortunately I don't own a van so had to partially strip it to get it home:





Got it home & took the rest to work & finished stripping it there:







Started by cutting the exhaust open to derestrict it:




Ground the main restricter out:




Then took the sound proofing & gauze out:




Next up I started cleaning all the plastics up & drained the fuel tank:




Then started preparing & repairing the panels, some had hairline cracks in them so I fibreglassed them from behind:





Got fed up with the tank so just got it shotblasted:



Took the top end off the engine to reveal why it needed a top end rebuild (one of the powervalves had broken & was clouting the piston):






The head was also in need of a good clean:



Next up I started making a rear hugger, got fed up with trying to use mesh as it wouldn't shape properly so used an old tyre instead Laughing :




Removed the swingarm bearings (ready for shotblasting) & welded a couple of mounting points for the hugger:





Then got back to work on the hugger again:





occasionally fitting it to the swingarm to check for fitment:




Then filled it all & smoothed it off:






G4 varnish applied:




Rubbed that down then release agent applied:




Wet laying the matting:



After curing was left with a negative mould:





Next I got some decals made up, painted the panels & tank & lacquered the decals in :









Got the frame, swingarm & exhaust back from being shotblasted & coated, the frame/swingarm have been dipped in nylon & the exhaust has been coated with greblon ( supposed to withstand temps up to 1200oc):






Then the rebuild starts Very Happy :







Heel plates polished & painted:



Back on with the build:








Brake calipers blasted & painted with new seals & nipples:




Painted the wheels, fitted with new tyre on the front & painted the disc centres:







New parts to go in, powervalves won on egay:






Started on rebuilding the top end:





Reed block, inlet manifold & carb back on:




Exhaust & generator cover refitted along with the front sprocket cover:




Painted the headlamp surround & ring:




Powervalves refitted:






Started making a bellypan:




Received a little prezzie from a mate in New Zealand:




It's a head & barrel from an RG150. Won't be fitting it yet as there needs to be modifications done as the powervalve housing is on the opposite side. I'll get the bike on the road first then start tinkering. Twisted Evil
That's as far as I've got for the moment, just need a throttle cable & battery to make the bike road worthy. Sorry for the long post & all the pictures but as I said earlier this has been ongoing for quite sometime & I didn't want to disrespect this forum by posting links to another one. Hope people like it thanks for reading. Very Happy Twisted Evil
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BenR



Joined: 24 Aug 2009
Posts: 59

PostPosted: Fri Dec 04, 2009 4:16 pm    Post subject: Reply with quote

Forgot to show what the bike looks like all together. Embarassed



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Darin
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Joined: 23 Nov 2006
Posts: 444
Location: Isle of Wight

PostPosted: Sat Dec 05, 2009 12:08 pm    Post subject: Reply with quote

Shocked That's bloody fantastic Ben - the bike looks superb and a real credit to your time and skill .... I wish I had both!! Laughing

Hell of a write up too, and great to see the whole process in 5 minutes Smile It would be great to see more of these strip and rebuild threads on DS - there must a few knocking around Smile If I ever find the time to tackle the SDR....

Let us know when it's finished and if you ever fancy showing it on one of the DS stands in 2010 Cool
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BenR



Joined: 24 Aug 2009
Posts: 59

PostPosted: Sat Dec 05, 2009 1:40 pm    Post subject: Reply with quote

Thanks very much. I have tried to keep the bike standard & original just modernising it here & there, although I have bought a banana arm from an RG125 FUN/P/R, don't know whether to fit it or not. I'll have to an eye out for your events next year, thanks for your compliments. Very Happy
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Crofty
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Joined: 19 Feb 2008
Posts: 331
Location: Stoke-on-Trent

PostPosted: Sat Dec 05, 2009 6:52 pm    Post subject: Reply with quote

Very interesting, and great work! An enjoyable thread.
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Breathing new life into an old Gamma!

http://www.rg250.co.uk
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BenR



Joined: 24 Aug 2009
Posts: 59

PostPosted: Sun Dec 06, 2009 1:22 pm    Post subject: Reply with quote

Thanks, not finshed yet but soon hopefully. I won a throttle cable on egay last night just hope it's the right one. Will get a battery then just need to finish the belly pan. Thumbs Up
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geoff37



Joined: 13 Dec 2006
Posts: 5
Location: belfast

PostPosted: Sun Dec 06, 2009 11:46 pm    Post subject: Reply with quote

fantastic thread and brilliant pic,s the bike looks stunning chum
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hi folks i own 2 gsx1100 katana,s 2 ns400r,s soon to be 3 ha ha , 3 250lc,s 1 350lc 1 350lc mk2 1 125lc mk2 , 2 mbx 125,s 1 tdr250 and a h2 750 triple .
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BenR



Joined: 24 Aug 2009
Posts: 59

PostPosted: Mon Dec 07, 2009 12:21 am    Post subject: Reply with quote

Thanks not long to go now. Wink
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BenR



Joined: 24 Aug 2009
Posts: 59

PostPosted: Fri Dec 11, 2009 5:11 pm    Post subject: Reply with quote

Bit of an update:

I had today off so I've been continuing with the belly pan for the bike.

I made the 2 sides from the mould I made earlier:



After scouring the internet & egay for bumper mesh none of it seemed to be very cheap so I got 3 disposable BBQs for 6 quid & used the mesh out of them:



After trimming the mesh to the width I needed I bonded it to 1 side first:



After bonding the second side on I flipped it over & laid matting/resin on the underside to make the floor:




Cut some more mesh to fit in the front & laid a couple of layers:




It looks a bit of a mess but once I've trimmed it all up & filled & shaped it smooth it'll be ready for taking a mould from it. I need to add a couple of bits at the back as well. I received a new battery the other day so I now have power, although the indicators & horn don't work & the bulbs in the rev counter have blown, I'm hoping it's just a fuse.





The break lights stay on for the mo as I think I need to adjust the rear brake light switch.
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BenR



Joined: 24 Aug 2009
Posts: 59

PostPosted: Tue Feb 02, 2010 6:24 pm    Post subject: Reply with quote

Bit of an update. I brought home some heavy duty commercial axle stands & decided to fit the SV shock. I'm not sure the pics will show the difference but it is quite substantial. Looks so much better & you can see the hugger a lot better. Still got loads of adjustment on the height as well.

Before:


After:
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BenR



Joined: 24 Aug 2009
Posts: 59

PostPosted: Wed Feb 10, 2010 11:56 pm    Post subject: Reply with quote

Last update.
I'm leaving it for now as I just want to ride it. Smile So all finished just got to go round make sure everything is tight & done up properly.



Eventually I'll get the wider rear wheel fitted & some nice new wavy discs & HEL braided lines. Also got the 150cc barrel & head for future tinkering.

Cheers Ben.
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Darin
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Joined: 23 Nov 2006
Posts: 444
Location: Isle of Wight

PostPosted: Sat Feb 13, 2010 1:10 pm    Post subject: Reply with quote

Brilliant Ben! The RG looks fantastic mate - let us know if she rides as good as she looks Surprised You know what I mean!! Laughing
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geoffrg



Joined: 08 Feb 2010
Posts: 100

PostPosted: Sat Feb 13, 2010 2:22 pm    Post subject: Reply with quote

stunning job mate , brilliant to see the progress on it and then the finisheed bike ,
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BenR



Joined: 24 Aug 2009
Posts: 59

PostPosted: Sun Feb 14, 2010 4:08 pm    Post subject: Reply with quote

Thanks for the compliments fellas. A little update:

I had the bike running today. Unfortunately there is petrol pissing out of the carb & it blows back every now & then. Shocked It's definitely over fuelling although I haven't touched the previous settings. Once running it runs really well any ideas?? Confused The exhaust is really noisy as well I'm guessing I should've coated the new gasket in fire gum?
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Howie



Joined: 18 Oct 2009
Posts: 511
Location: Kwaksville

PostPosted: Sun Feb 14, 2010 8:55 pm    Post subject: Reply with quote

Hi Ben, sounds like you need to have the carb off to check the level. Did you have the tank sealed? If not it could be something as simple as c**p getting through the filters & keeping the floats open.

I wouldn't worry about the exhaust until you have got the carb sorted.

Howie
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