Rebuilding my '93 RC36

I though I'd start this thread with two or three photos and then top it up when I've got a few minutes.

I tank slapped myself into a low side drop on a track day in Aug '06. Prior to this incident, the bike looked like this:

http://www.vfrdiscussion.com/forum/uploads/1279993817/med_gallery_5709_5496_2430.jpg

Soon after the incident, I got posted and didn't really touch it for 3 years other than slowly shopping for bits on Ebay. Got a fairing support frame for £6.00 so sometimes it works.

Anyway, 8 weeks ago I finally got stuck in and I'm now at the point of paint. I solvent welded a bunch of the panels back together and added tabs where they were broken off etc. Where the panels were too far gone (spread in small flakes down the track), I got 2nd hand panels and fixed them up.

Can you tell what it is yet?

http://www.vfrdiscussion.com/forum/uploads/1281214856/med_gallery_5709_5496_336963.jpg

I also thought I'd play with the airbox as I've done a left exit exhaust and put in a foam filter. Probably just annoy me after a while, but I like fiddling with things.

http://www.vfrdiscussion.com/forum/uploads/1281214856/med_gallery_5709_5496_115984.jpg

Anyway, more to come. It's being sprayed in yellow and the colour is really good so far. Got the tank, seat cowl and two belly panels painted. All the back end panels are next (tomorrow) and then the mid and uppers.

More photos to come. I took a few just to remind myself how to put it back together.

Stew

Will be looking for completed pics. Did you fab the left exit exhaust? Have any pics?

Nice Work!
Would love to know how the air box mods work out. I have a '97. :fing02:

The exhaust system is from Sandy Bike Spares in the UK. It isn't too bad but you couldn't just bolt it on and ride.

Well, I suppose you could, but you'd be seriously down on power. The joins from the two front downpipes to the centre section were terrible. You can read up about it in my exhaust thread:

http://www.vfrdiscus...__1#entry661478

Have a look in my gallery for more photos. This week I'll post a few in this thead with descriptions when I get a spare hour or so.

Stew

[image: View Post]93 VFR750 RC36, on 07 August 2010 - 06:43 PM, said:

I tank slapped myself into a low slide drop on a track day in Aug '06. Prior to this incident, the bike looked like this:

http://www.vfrdiscussion.com/forum/uploads/1279993817/med_gallery_5709_5496_2430.jpg


Stew


Man, that thing was sweet, good luck and hope it looks anywhere near as nice when your done! :fing02:

Well, put it this way, it'll be hard to miss.

I always wanted a yellow VFR as I though the best 800s were yellow. At the moment, I'm 4 panels away from a full paint job and it's looking pretty good.

My painting skills probably aren't up to a classy metalic blue sports-tourer but a paint job that will distract any onlooker from any minor imperfections is well within my skill set. It'll definitely be a bit more SPORTS than tourer in theme but I won't say more than that until I have photos to post.

It'll probably look a bit odd with Givi luggage fitted but I have ordered a bit of extra paint so I may just paint the lids yellow to match.

Stew

Here are a few more photos with commentary:

The first goal once I'd stripped the panels off was to replace the old exhaust. 17 years of corrosion on the front studs/nuts meant that even with heat + plusgas + more heat etc, I snapped off two studs at the base of the nut as shown here. Fortunately enough of the stud was left that I could use more heat + plusgas + pipe freeze (x several cycles) and both came out with vice grips in the end. More detail can be seen in my exhaust thread.

http://www.vfrdiscussion.com/forum/uploads/1281214856/med_gallery_5709_5496_108601.jpg

Here's a couple of pictures of the Sandy left-exit system installed. See my thread about the modifications needed to correct the poor joins in the centre section.

http://www.vfrdiscussion.com/forum/uploads/1279993817/med_gallery_5709_5434_79224.jpg

http://www.vfrdiscussion.com/forum/uploads/1279993817/med_gallery_5709_5434_282660.jpg

http://www.vfrdiscussion.com/forum/uploads/1279993817/med_gallery_5709_5434_383485.jpg

http://www.vfrdiscussion.com/forum/uploads/1279993817/med_gallery_5709_5496_310512.jpg

Here's a view of the 929 shock (rebuilt by Jamie Daugherty with Racetech Gold valves and a stronger spring) installed. You can't see it here but the metal forward half of the battery box has a pair of tabs on it's forward side used to mount a relay. I had to bend them flat and then mount the relay on the RH side of the battery box. A bit of fiddling and bending and the whole thing fits with good clearance around the shock and new exhaust downpipes.

http://www.vfrdiscussion.com/forum/uploads/1279993817/med_gallery_5709_5496_13764.jpg

Carbs out. They've now been rebuilt with a Factory Pro jetting kit. I'll get the bike on the dyno and do a pull with the spud in and out and see where I am with fueling. I've gone to a 132 main jet and put the needle on the 3rd from top setting (stock airbox/exhaust recommends 2nd).

http://www.vfrdiscussion.com/forum/uploads/1281214856/med_gallery_5709_5496_37312.jpg

http://www.vfrdiscussion.com/forum/uploads/1281214856/med_gallery_5709_5496_290786.jpg

http://www.vfrdiscussion.com/forum/uploads/1281214856/med_gallery_5709_5496_9555.jpg

Forks off for rebuild:

http://www.vfrdiscussion.com/forum/uploads/1281214856/med_gallery_5709_5496_317839.jpg

Back on with Racetech 0.95 kg/mm springs and CBR 600 F3 internals (Cap and rebound rod/valve in VFR cartridge). 5w fork oil.

http://www.vfrdiscussion.com/forum/uploads/1279993817/med_gallery_5709_5496_39473.jpg

And now for the cool bit. Here's the tank in primer. It's now painted and looking brilliant. I've got a bunch of photos on my camera to upload and then I'll continue the commentary.

http://www.vfrdiscussion.com/forum/uploads/1281214856/med_gallery_5709_5496_93743.jpg

Tonight I finish putting the airbox back together with UNI filter and it's time for first engine start. I've got lots of panel repair/paint photos to upload and I'll do that over the next couple of days and post a few more key photos.

Stew

great progress so far!!

[image: View Post]ss_burns, on 10 August 2010 - 12:14 PM, said:

great progress so far!!


Yes, can't wait to see the paint job!!

[image: View Post]93 VFR750 RC36, on 10 August 2010 - 10:25 AM, said:

Here are a few more photos with commentary:

http://www.vfrdiscussion.com/forum/uploads/1279993817/med_gallery_5709_5434_282660.jpg



You smug little showoff. That's a beaut setup right there. Carb sync doesn't scare me. valve adjustments don't scare me. Exhaust rebuilds do!

Looks great. I had a 93 before my 96, the diff's are small but I always did like the sharper lines better. I'd get one in a second.

She runs!!!

I just finished the installation of the carbs, airbox + filter and tank this evening. 1/2 a tank of 97 RON with a good dose of fuel system cleaner (to get any bits of varnish etc that I missed) and I called my better half out to the garage to witness the fire up.

A couple of seconds cranking to get the fuel through the lines to the carb and "thump . . thump . . GRRRRROWL !" A minute on the choke and she settled into a nice deep burble as if to say, "What were you worried about, I'm ready for some riding!" About 5 cm/Hg between carbs on the Carbtune Pro, but that's not a big problem to solve. A bit of fiddling and she'll be good to go.

Here's the carbs and bits going in.

http://www.vfrdiscussion.com/forum/uploads/1281481093/med_gallery_5709_5496_325329.jpg

http://www.vfrdiscussion.com/forum/uploads/1281481093/med_gallery_5709_5496_502741.jpg

http://www.vfrdiscussion.com/forum/uploads/1281481093/med_gallery_5709_5496_63763.jpg

http://www.vfrdiscussion.com/forum/uploads/1281481093/med_gallery_5709_5496_63572.jpg

I'll now let her sit for 24 hours with the cleaner in the system and then do the carb balance. Still got some painting to do anyway so I'll fit in the mechanical fiddling in between coats.

Speaking of bodywork, here's some photos:

First, a view of a solvent weld from behind (I may have overdone the build up on the back, but better too strong than not strong enough for my first set of panels) and then the painted side. Both rear side panels were cracked, but one a lot worse than the other as you can see.

http://www.vfrdiscussion.com/forum/uploads/1281481093/med_gallery_5709_5496_105066.jpg

http://www.vfrdiscussion.com/forum/uploads/1281481093/med_gallery_5709_5496_73722.jpg

http://www.vfrdiscussion.com/forum/uploads/1281481093/med_gallery_5709_5496_79351.jpg

http://www.vfrdiscussion.com/forum/uploads/1281481093/med_gallery_5709_5496_194085.jpg

Front fender next to the dish rack. I was getting my better half's opinion on the paint and she likes it.

http://www.vfrdiscussion.com/forum/uploads/1281481093/med_gallery_5709_5496_56626.jpg

A few other pictures of bodywork.

http://www.vfrdiscussion.com/forum/uploads/1281214856/med_gallery_5709_5496_1410226.jpg

http://www.vfrdiscussion.com/forum/uploads/1281214856/med_gallery_5709_5496_803082.jpg

http://www.vfrdiscussion.com/forum/uploads/1281214856/med_gallery_5709_5496_2408553.jpg

This was the tank, seat and seat cowl fitted just to check everything was fine.

http://www.vfrdiscussion.com/forum/uploads/1281214856/med_gallery_5709_5496_459700.jpg

http://www.vfrdiscussion.com/forum/uploads/1281214856/med_gallery_5709_5496_804994.jpg

Here's a picture of the one good CBR 600 fork top. The other rebound screw was damaged and I'll put in the replacement tomorrow. I'll be checking fork oil levels at the same time. Got a syringe and bit of small fuel line so I can get them matching exactly.

http://www.vfrdiscussion.com/forum/uploads/1281214856/med_gallery_5709_5496_2531326.jpg

Anyway, that's all I've got for now so I'll get back to the bike so I can provide you with better updates as it comes together.

Stew

OK, a couple more.

Just another view 10 minutes before startup:

http://www.vfrdiscussion.com/forum/uploads/1281481093/med_gallery_5709_5496_120052.jpg

Here are some pictures of one of my upper panels that I will paint tomorrow. The windscreen fitting bit was broken off in the incident so it's been solvent welded back on and the joint blended on the visible side. This was my first solvent weld joint and I think I'll leave it with the little blemishes in it. Adds a bit of character :blush: .

http://www.vfrdiscussion.com/forum/uploads/1281481093/med_gallery_5709_5496_143869.jpg

http://www.vfrdiscussion.com/forum/uploads/1281481093/med_gallery_5709_5496_265702.jpg

Now I really am going to bed.

Stew

Aren't those keys scratching the tank???? :ohmy:

Looking great! I appreciate the hard work you have put into this.

followed the link from the 'exhaust thread'

kudos on the work...

Just a couple of RC36s that have recently been on Ebay UK. A bit of custom paint scheme inspiration for everyone.

http://www.vfrdiscussion.com/forum/uploads/1281585305/med_gallery_5709_5496_1914.jpg

http://www.vfrdiscussion.com/forum/uploads/1281585305/med_gallery_5709_5496_38453.jpg

http://www.vfrdiscussion.com/forum/uploads/1281585305/med_gallery_5709_5496_26577.jpg

http://www.vfrdiscussion.com/forum/uploads/1281585305/med_gallery_5709_5496_24593.jpg

Considering my base colour is yellow, it probably doesn't take much imagination to figure out which scheme it'll end up in. Hopefully I'll have photos for you by the end of next week.

Carbs now balanced within 1cm/Hg. Fuel screws set at 2-1/4 and idle seems nice with off idle response quick. I'll get the idle mixture set with an exhaust gas monitor and then see if it'll pass MOT.

Stew

Great progress! :fing02:

Question, do you plan to shoot some clear over the yellow shown? :huh:


BR

Haven't decided on the clear yet. I'm waiting for the 7 day cure before putting decals on. I like the slightly matt look but some reports on the net say that Krylon clear finishes slightly matt so that may work.

I guess I'm just winging it beyond initial paint and decals.

Stew

I've always been partial to the ROTHMANS HONDA colors scheme... good choice

I've always liked Castrol, Rothmans and Camel. Mine will be a Camel (for now).

Got a picture of Joey Dunlop on a Castrol RC30 road racing (Isle of Man TT?) with both wheels in the air on some country lane.

Awesome!

Almost there! Rode the bike up the street and back today. No front fairing or lights, but hey, it sounded good and it was nice to be on it again after all this time.

Here's the rear bodywork back on. Took some real messing around as I discovered why the two main mounting tab/hoops always get broken. The subframe doesn't fit the bodywork! I thought a Honda was a precision product. Mind you, the gear driven cam V4 more than makes up for a bit of subframe inaccuracy.

Anyway some precision engineering from me (plastic hammer) had the subframe modified and now my panels fit the way they are supposed to.

http://www.vfrdiscussion.com/forum/uploads/1281585305/med_gallery_5709_5496_125279.jpg

Bit too much reflection from the flash, but 4x carbs balanced within 1cm/Hg. Running like a champ.

http://www.vfrdiscussion.com/forum/uploads/1281585305/med_gallery_5709_5496_1444.jpg

My spray bay in my messy garage. Soon to be tidied up but I'm on a roll so the bike gets done first.

http://www.vfrdiscussion.com/forum/uploads/1281585305/med_gallery_5709_5496_491959.jpg

The final panels hanging in the spray bay. Got an electric immersion heater keeping it warm and dry to help speed the cure.

http://www.vfrdiscussion.com/forum/uploads/1281585305/med_gallery_5709_5496_2420383.jpg

http://www.vfrdiscussion.com/forum/uploads/1281585305/med_gallery_5709_5496_1541921.jpg

Belly panels on the kitchen floor before going on the bike.

http://www.vfrdiscussion.com/forum/uploads/1281585305/med_gallery_5709_5496_365308.jpg

On the bike. This is when I found the forward down-pipe was too close to the belly panels. See http://www.vfrdiscus...__1#entry727889 for details.

http://www.vfrdiscussion.com/forum/uploads/1281585305/med_gallery_5709_5496_275310.jpg

Here she is as I left her 10 minutes ago. The temptation to keep working is intense but I need those other panels to cure properly. Too much work to mess up the paint now.

http://www.vfrdiscussion.com/forum/uploads/1281585305/med_gallery_5709_5496_2720782.jpg

http://www.vfrdiscussion.com/forum/uploads/1281585305/med_gallery_5709_5496_163671.jpg

Anyway, I think it's starting to look pretty good. I hope everyone likes it. Gotta keep the old veefer looking fresh and ready to ride!

Hopefully I'll be able to post completion pictures soon. Can't wait.

Stew

Getting closer!

Just rebuilt a bunch of the front end. Will wait another day or so before doing any more. Don't want to chip or otherwise damage the new paint.

I left off the side panels to keep curing. I've also lost the two forward fender bolts somewhere. I also can't find the two little black plastic cap bits that fit on the inside rear lower edge of the windscreen. Bloody annoying things like that are! I know I set them somewhere "safe" the other day and now there's no sign.

Regardless, I'll probably finish up the project on Tuesday or Wednesday.

Anyway, this is where I am now:

http://www.vfrdiscussion.com/forum/uploads/1281812977/med_gallery_5709_5496_2592518.jpg

http://www.vfrdiscussion.com/forum/uploads/1281812977/med_gallery_5709_5496_1730951.jpg

http://www.vfrdiscussion.com/forum/uploads/1281812977/med_gallery_5709_5496_1537907.jpg

http://www.vfrdiscussion.com/forum/uploads/1281812977/med_gallery_5709_5496_1513638.jpg

http://www.vfrdiscussion.com/forum/uploads/1281812977/med_gallery_5709_5496_2335246.jpg

http://www.vfrdiscussion.com/forum/uploads/1281812977/med_gallery_5709_5496_2176849.jpg

Hope you all like it so far. I'm loving it. Took it for a quick ride today as it is, just around the neighbourhood. Felt great to be back on it and the suspension feels different already. I can't wait to get it out on the road.

Stew

She's going to be a beauty. Love the yellow, although I don't care too much for the decals and stickers -- I think cleaner looks better. The '93 is one of my favorite vfr's. Great job and best of luck!

Looks great in yellow, well done :fing02:

[image: View Post]93 VFR750 RC36, on 13 August 2010 - 11:03 AM, said:

Got a picture of Joey Dunlop on a Castrol RC30 road racing (Isle of Man TT?) with both wheels in the air on some country lane.

:worthlesswithoutpics:

I'M DONE!!!!!!


Well, almost. Just have the tank decals to put on.

I finished in the dark so you'll have to wait for better photos. However, I couldn't resist these two even in the dark.

http://www.vfrdiscussion.com/forum/uploads/1281977735/med_gallery_5709_5496_799947.jpg

http://www.vfrdiscussion.com/forum/uploads/1281977735/med_gallery_5709_5496_2575371.jpg

I'll get some more in daylight with the tank decals on. She should be on the dyno on Friday and then I'll be able to report on the success of the carb/filter/exhaust part of the rebuild.

Stew

Looks great! I'm a sucker for race replica's!

Well, here she is.

http://www.vfrdiscussion.com/forum/uploads/1281977735/med_gallery_5709_5496_2016209.jpg

http://www.vfrdiscussion.com/forum/uploads/1281977735/med_gallery_5709_5496_2642137.jpg

http://www.vfrdiscussion.com/forum/uploads/1281977735/med_gallery_5709_5496_122943.jpg

http://www.vfrdiscussion.com/forum/uploads/1281977735/med_gallery_5709_5496_2083902.jpg

Just neet to get the MOT sorted out on Friday and I'm back on the road. Can't wait.

Stew

Great work on all of it, I'm thinking of getting my 929 rear shocks rebuilt by Jamie as well.
That rear fender is quite long, I'd chop it up the the bottom of the license plate unless there are laws against it

Way ahead of you on the fender. The law here requires the reflector so I've ordered another one (this one's nut is rusted solid to the stud) and then I'll put it right under the plate and contour the fender to fit. That huge chunk of black plastic will be pared down to size in a couple of days.

Stew

GREAT JOB !!!!!!!!!!!!!!!!!!