Sunrise - 1977 GL 1000

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Mark King
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Re: Sunrise - 1977 GL 1000

#46

Post by Mark King »

Today is July 24. The rust in this tank was concentrated along the top. The sides and bottom cleaned up almost immediately but I have had the electrolysis on-going working on the top 24-7.

I vacuumed the tank clean every day for three days. This included a rinse and a scrub with a wire brush where I could reach and then vacuuming up the debris in the bottom of the tank.

The first day the electrolyte was a horrible rust color with a ring of oily crud along the top. It lessened each day until by day four the electrolyte didn't change color. I have had the same batch in the tank now since the fourth day.

This morning finally there was only one rust flake attached to the anode and a bunch of rust dust.

I stuck it back in for one for day and if there are no flakes tomorrow I will be rinsing and cleaning the tank and filling it with an oily gas mixture to hold it for however many more years and dollars it takes me to complete this rebuild.

However, for anyone considering electrolysis on an old tank the messages are - you don't have to remove the tank or the petcock and you need to fill it to the brim and let it work. The first day it actually boiled off some of the electrolyte, it was that full of rust and crud. I haven't had that problem since. I also noticed for the first day the charger was really pumping out the juice. That settled down to a mere minor trickle after a few days.

I'll post some or one pic of the tank after.
M King
1977 GL1000 - Under s l o w restoration
1981 CB900C - Rebuilt but stripped spark plug thread
2002 VTX 1800 -Current Rider
1984 GL1200 Aspencade - Restored and Sold
1980 Suzuki GS850G - Restoration on hold
1985 750 Nighthawk SC - Sold
1976 GL1000 - Yellow - Restored and Sold (regret the sale)
1981 GL1100 - Naked - Restored and Sold
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Re: Sunrise - 1977 GL 1000

#47

Post by robin1731 »

Just be sure to do it in a well ventilated area. The electrolysis produces hydrogen.

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Re: Sunrise - 1977 GL 1000

#48

Post by rcmatt007 »

makes for fun explosions.... but it burns clean
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Mark King
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Re: Sunrise - 1977 GL 1000

#49

Post by Mark King »

So the end of the tank cleaning.

I kept the electrolysis going until I had no more rust particles building up on the electrode.

It took awhile and in the last two weeks there was only one small piece of rust every odd day but finally there was none.

Then work and weather conspired against me until finally about two weeks ago I was able to flush and scrub the tank.

It sat for a few week with the solution in it before I could clean it out and it caused no harm.

Clean water flush until the water was clear and then I sprayed a heavy dose of wd 40 onto the water in the tank so it coated the tank as I vacummed the water out from the bottom.

Hair dryer for about five minutes then I filled it with gas, oil and stabilizer.

Tank is shiny and new looking although it has a few small pits. But no leaks.

Next up, when I get a chance, I have to rebuild the starter.
M King
1977 GL1000 - Under s l o w restoration
1981 CB900C - Rebuilt but stripped spark plug thread
2002 VTX 1800 -Current Rider
1984 GL1200 Aspencade - Restored and Sold
1980 Suzuki GS850G - Restoration on hold
1985 750 Nighthawk SC - Sold
1976 GL1000 - Yellow - Restored and Sold (regret the sale)
1981 GL1100 - Naked - Restored and Sold
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Re: Sunrise - 1977 GL 1000

#50

Post by Rat »

Glad to hear 'retirement' is going well for you ....

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Re: Sunrise - 1977 GL 1000

#51

Post by raiddrten »

Maybe I should be more worried about hydrogen explosions than I am, but as a matter of observation,the electrolyte encases the bubbles with an occasional bubble of maybe a teaspoon coming to the surface. My garage is certainly not air tight enough to gather any significant amount of gas in one spot. Besides that, the h2 will be up on the ceiling right away and floating to the sky after that.

A battery on a charger or one that you hook up backwards is much more dangerous in that the h2 can build up in the case. I have seen two batteries blowup in my lifetime on the farm. One was sitting overnight on a charger,and the other was a jump start---with the dead battery hooked up backwards. I was the hired guy doing as I was told, but had the common sense to dive for a mud puddle and smear mud on my face. No burns at all...

The best way to speed the process is use a large diameter annode and clean the thing every few hours. Adding some PineSol to the electrolyte also helps things out quite a lot as it gives dissolving properties for the gunk in the tank that is not rust.
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Re: Sunrise - 1977 GL 1000

#52

Post by ericheath »

Hydrogen is so light and small that it will be up and gone before any could accumulate to a dangerous level. There is also the oxygen component, but unless you have a pretty powerful setup, you’re safe. If it was this easy to do, we’d all be doing it to power our cars and homes.
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Mark King
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Re: Sunrise - 1977 GL 1000

#53

Post by Mark King »

Phew, time flies when life is fubar. Belated Merry Christmas and Best Wishes for the New Year to one and all!

Back at this project again for a few hours over the holidays.

I purchased a starter rebuild kit as the entire brush plate and assembly was missing from the starter - which was itself in pieces - and I have taken the entire starter apart, cleaned it up and am now re-assembling.

The kit did not come with brush screws - that teeny tiny screws that attach the brush wires to the plate and the positive wires in the starter - and of course the screws are missing from the bucket of parts that came with the bike.

My parts diagram just shows the assembly and doesn't tell the screw size. I don't have easy access to any engine electric supplier.

Does anyone know what size and type of screws are required and / or is there someplace that sells them on-line? DONT BOTHER WITH AN ANSWER SEE NEXT POST

Thanks
Last edited by Mark King on Sat Dec 29, 2018 2:51 pm, edited 1 time in total.
M King
1977 GL1000 - Under s l o w restoration
1981 CB900C - Rebuilt but stripped spark plug thread
2002 VTX 1800 -Current Rider
1984 GL1200 Aspencade - Restored and Sold
1980 Suzuki GS850G - Restoration on hold
1985 750 Nighthawk SC - Sold
1976 GL1000 - Yellow - Restored and Sold (regret the sale)
1981 GL1100 - Naked - Restored and Sold
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Mark King
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Re: Sunrise - 1977 GL 1000

#54

Post by Mark King »

Further to my post from yesterday. I went to the local auto store and found a reasonable replacement screw and lock washer for each brush set.

They took an M3 screw and I bought the shortest one I could find. The heads are smaller than what you would hope but the lock washer seemed to do the job.

Reassembled the starter and it works like a new one.

Timing belts, carbs, valve clearance and ignition next up on the work list. Once I get the engine running I will tackle the other stuff. Although I may do some indoor body panel sanding over the winter to stay warm.
M King
1977 GL1000 - Under s l o w restoration
1981 CB900C - Rebuilt but stripped spark plug thread
2002 VTX 1800 -Current Rider
1984 GL1200 Aspencade - Restored and Sold
1980 Suzuki GS850G - Restoration on hold
1985 750 Nighthawk SC - Sold
1976 GL1000 - Yellow - Restored and Sold (regret the sale)
1981 GL1100 - Naked - Restored and Sold
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Graham Cracker
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Re: Sunrise - 1977 GL 1000

#55

Post by Graham Cracker »

:popcornx2 Your patience is amazing...you'll be riding it this summer action1
Mark

1975 GL 1000 Candy Antares Red
1976 GL 1000 Sulfur Yellow
1977 GL 1000 Pearl White
1978 GL 1000 Candy Limited Maroon
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Mark King
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Re: Sunrise - 1977 GL 1000

#56

Post by Mark King »

I'd like to think I'll be riding it this summer but - long way to go - the 900 engine needs to be pulled so I can fix the spark plug hole - the VTX needs a little work - we have another election coming up in the fall, which means the campaign starts almost now and just intensifies, so ...

My advice is, please don't hold your breath on this one - it will very likely be fatal!

Cheers

Mark
M King
1977 GL1000 - Under s l o w restoration
1981 CB900C - Rebuilt but stripped spark plug thread
2002 VTX 1800 -Current Rider
1984 GL1200 Aspencade - Restored and Sold
1980 Suzuki GS850G - Restoration on hold
1985 750 Nighthawk SC - Sold
1976 GL1000 - Yellow - Restored and Sold (regret the sale)
1981 GL1100 - Naked - Restored and Sold
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Mark King
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Re: Sunrise - 1977 GL 1000

#57

Post by Mark King »

Just a quick heads up tonight. After years of being frustrated by trying to repair the old plastic panels on these bikes I finally found something that seems like it works - Q-Bond.

One panel on the 77 was missing a tab and part of the panel that broke off with the tab.

I was at a trade show last year and picked up a sample of Q-Bond and haven't had a chance to try it.

Sanding and working on these panels I thought I'd give it a shot.

I sanded the break, then washed it with rubbing alcohol. Then I quickly made up a couple of popsicle sticks with tape on them and a couple of light clamps to form a barrier / mold.

Dropped in the powder and added the glue and within seconds pulled the mold off and the stuff was stuck. Really stuck.

Gave it a quick sanding and tried to break it off. Not moving.

This is a just rough job to try it out. Had I known it would work so well I would have been a bit more precise rather than sitting at my desk. I have to add more Q-Bond to fill the gaps, sand it sooth, and then I will fabricate the tab and attach it and see how that works and I'll report back.

You can see from the Inside pic how deep the break was.

More later ...
Broken.jpg
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Inside 1.jpg
Inside 1.jpg (127.47 KiB) Viewed 171 times
Outside 1.jpg
Outside 1.jpg (93.08 KiB) Viewed 171 times
M King
1977 GL1000 - Under s l o w restoration
1981 CB900C - Rebuilt but stripped spark plug thread
2002 VTX 1800 -Current Rider
1984 GL1200 Aspencade - Restored and Sold
1980 Suzuki GS850G - Restoration on hold
1985 750 Nighthawk SC - Sold
1976 GL1000 - Yellow - Restored and Sold (regret the sale)
1981 GL1100 - Naked - Restored and Sold
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Mark King
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Re: Sunrise - 1977 GL 1000

#58

Post by Mark King »

Used the Mouse sander on it today with fine paper.

I'm impressed.
Sanded.jpg
Sanded.jpg (120.41 KiB) Viewed 150 times
Now to build the tab and attach it.
M King
1977 GL1000 - Under s l o w restoration
1981 CB900C - Rebuilt but stripped spark plug thread
2002 VTX 1800 -Current Rider
1984 GL1200 Aspencade - Restored and Sold
1980 Suzuki GS850G - Restoration on hold
1985 750 Nighthawk SC - Sold
1976 GL1000 - Yellow - Restored and Sold (regret the sale)
1981 GL1100 - Naked - Restored and Sold
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Mark King
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Re: Sunrise - 1977 GL 1000

#59

Post by Mark King »

And so it ends in failure.

After building the tab and attaching it and sanding everything it hooked well on the bike but when I reefed on it a bit - it broke off.

It was firm until that point and if I hadn't pulled on the bottom of the panel and forced it a bit, it may have been ok.

Part of the problem may be that I made it too thick. I used a paint stir stick as a mold for the tab and probably should have used a popsicle stick. It had no wiggle room in the bracket. So I might try again.

But for now, this is in the "Lose" column.
fail.jpg
fail.jpg (104.47 KiB) Viewed 134 times
M King
1977 GL1000 - Under s l o w restoration
1981 CB900C - Rebuilt but stripped spark plug thread
2002 VTX 1800 -Current Rider
1984 GL1200 Aspencade - Restored and Sold
1980 Suzuki GS850G - Restoration on hold
1985 750 Nighthawk SC - Sold
1976 GL1000 - Yellow - Restored and Sold (regret the sale)
1981 GL1100 - Naked - Restored and Sold
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Re: Sunrise - 1977 GL 1000

#60

Post by OCR »

A plastic welding kit would give better results.
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