Hold-ups

Business workload has improved even though the bike build hasn't, it's getting little like my 1969 swb 4.6 xj6 series1, Jaguar with manual gearbox/overdrive. Which has been stored in the garage along side where the Bandit is kept for some years now but unlike the Bandit have no plan to start working on it yet.

Few months ago I brought the undertray which you see fitted in the above photo (the photo doesn't do it justice). It's made for the Bandit 600 so needed to do some cutting and filing to get it to fit, I've left the pillion grab bars in place as I didn't what to cut them off at this moment in time. There are areas where the undertray doesn't meet the b4 bodywork very well if not at all, also where the battery meets the undertray  the tray will need cutting-out and reshaping so the battery can be refitted. As well as this am reshaping the rear of the undertray where it also meets the rear light and the two fixing bolts for the rear b4 bodywork. To do this' I need to fabricate number of backer plats which allows you to lay-up the repair the same way the undertray was built--gelcoat first. Which hopefully will means very little finish work will be required.

I google' moulding material's but couldn't find anything that would make my life any easier so decided to return back to the old trusted car body filler to fabricate the backers. The photos below shows some of the backer plates I've made-up so far, these still need some finishing off, i.e. more reshaping, smooth-out and painting.

When I get to re-fibreglassing the undertray the backer plats are waxed with releasing compound and then fixed to the outside as tight as possible to the undertray which is first turn-up-side-down, then lay two coats of black gel coat into the repair areas, once the gel coat becomes tacky start to lay-up the fibreglass fabric mating, when the repairs are done let dry for 24! Hours and then removed and discarded the backer plates.

I've been working on the swingarm on and off over sometime now regards to polishing and possible other ideas which is why I haven't cut anything off yet? . The photo shows how the swingarm might look like but since this photo was taking it's been re-sander back again before being re-polishing again.

 

 

I seam to be coming across more then my own fair share of problems during this build and this is the latest' After finishing the sprockets and chain setup? I started sanding-down the mould edges that are left behind in the rear-wheel casting process and needed to remove the brake disc to do so I had to undo the Allen-key-type bolt's head of which I managed to removal three of them but the other two bolts were partly seized and the Allen-key bolt head was rounded off so had to drill the head out and the last started to come out but as I thought it was coming out it snap-off.
I do have a set of extractors somewhere but can't find them so looks like I have to buy new set.
Again this happens a while ago' it pays sometimes to walk away from a problem but not this long.

The June to October time is busy time dealing with car and van MOTs and many other thing that needs doing at this time each year and now I hoping I can spend bit more time on the bike, lets see?...................