14) Looking like a Motorcycle

I have been learning about making side panels out of plastics, how to apply bondo to plastics, and if you rush it can really look like crap.  

I initially was thinking I could make the side panels from sheet metal.  

 This was looking kind of OK but my skill level had a lot to be desired. Not to mention the amount of bondo going to be required to cover up my learning curve.
 So I started thinking about fiberglass. Watched tons of videos of various DIY guys at different skill levels and how easy they all made it look and how messy as well. In my research I came across this one guy with a flat sheet of plastic, some simple shears, and a heat gun making very complex shapes. WHAT! Thermoform ABS plastic looked like some pretty cool stuff. I ordered a sheet and found out how easy it was to work with, so decided to go plastic. As I discovered the Honda Goldwing plastic was also made of ABS and with heat it to could be shaped, so what can I use to make my life easier?

 

So with a jig saw, shears and patients as well as some heat the Honda panels took on a new shape.


The next thing I discovered is plastic welding or fusing and how simple it was. First I found a little acetone will instantly fuse two pieces of thermoform plastic together.








Than I found PlastiFix. This stuff is very cool but the fumes are strong and toxic. You can bond any two pieces of plastic or fill holes, repair cracks or just cover up any mistakes or screw ups. this is good stuff.

So the bike is really coming together. The next big thing is to totally take it apart, have the engine rebuilt to make it fresh and decide if I will try my hand at painting. My initial bondoing and prime is kinda of OK. But!

13) Some Progress and a bunch of Firsts

So things have been progressing slowly but forward;

The bike has really started to come together; Added cooling water (only small leaks), battery charged up (going to need a new one), oil level good (needs to be changed), and gas in the tank.

NO LEAKS!

   It was time to see if it will start(?)

And than on the road and up the street

The seat is now upholstered

Making progress on the side panels

And planning on the final look

Still need to finish all the side panels, have the component powered coated and painting. Than go to DMV to get it road legal.  Still plan to have the engine overhauled to make the bike reliable. 

Planning a trip to with my brothers in June of 2016 so I have a target for completion. 

12) The Project is still in Progress, Really!

I know it has been awhile.

Yes the Project has continued and has progressed quite far.

The wiring, which I focused on in my last update, (yes I know September last year), is basically done. I haven't blown any fuses recently, so I think I found all (hopefully all) my mistakes. All the lights work, radio works, all indications light up, and the blinkers blink. The motor turns over and I recently wired the spark plugs and had spark at all 6 plugs. So I still need to add coolant and complete installation of fuel lines from the tank. And YES I need to put fuel in the tank. I have been holding off because once I add gas to the tank repairs to it become more difficult. Yes I know until I add fuel I will not know if there is a problem with leaks. And I really do not want to use water as it is very hard insure it is all out. 

Well what have I done?         

I made a luggage rack
for the back of the bike.

  I manufactured supports
for the mufflers

And I mounted the saddle bags

You may be asking what have I been doing with the rest of my time.

Well I started riding my bicycle,  So far I have completed three organized rides. One in Solvang (52 miles), one in Chico (62 miles), and the local Tour of the Unknown Coast (62 miles) which I road with my biking partner Doug. The training for these has been keeping me busy. We ride about 90 miles a week just to try to stay in shape and keep our aging bodies moving.  

Solvang 1/2 Century March 2015

Humboldt County TUC Metric Century
May 2015

Chico Wildflower Metric Century April 2015

So now I need to get back to working on the other bike the motorcycle. In the next few weeks I hope to be adding coolant, finally adding fuel to the tank and for the first time starting it up (my fingers are crossed). Once I get it running I will take it to the upholstery shop to get the seat done. Than focus on the side panel, which I am thinking I will try to learn to fiberglass. Maybe not?