"Parts Bike" a '77 rebuild thread

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robbie202
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"Parts Bike" a '77 rebuild thread

#1

Post by robbie202 »

hey everybody, i've been away for a while with some long term commitments but i made some progress on the build.
'77 GL1000
'03 Sportster
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Re: "Parts Bike" a '77 rebuild thread

#2

Post by robbie202 »

this bike is now named "Parts Bike" because i had two abandoned '77's that i am putting together to make one good one.
along the way i figured out that the "Riding Bike" had been crashed at some point and had some damage to the frame that i was not comfortable with so i switched mid-project and the other bike became the one that was getting fixed.
Last edited by robbie202 on Sun Nov 24, 2019 3:54 pm, edited 2 times in total.
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Re: "Parts Bike" a '77 rebuild thread

#3

Post by robbie202 »

here are some photos
1: "Parts Bike" photo from craigslist. "running when parked in 1995"
2: how it looked when we uncovered it from the junkpile
3: reference picture of a new one
4: the "Riding Bike" after a very nice restoration from Randy's Cycle Service in Virginia. there is a youtube video on his site of this repair.
5: the "Riding Bike" on the day i got it after sitting outside for years. rode it home...but just barely.
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riding_bike.jpg
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Re: "Parts Bike" a '77 rebuild thread

#4

Post by robbie202 »

so the backstory of the two bikes is similar. Riding Bike was purchased by a guy who lives close to my work. his dream vacation was to ride the best road on the best bike so he had this unit restored and rode the tail of the dragon. afterwards he just parked it.

Parts Bike is the exact same thing. this dude bought the bike, rode to california and back from DC, and threw a tarp over it in 95. he literally never saw it again until we dug it out on the day of purchase. that's why the photo in the ad was so old. it has never ran since i had it i just wanted it for spares.

that was back in 2012. i rode the riding bike for a while before it broke down properly then i was either cycling or riding the sportster.
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Last edited by robbie202 on Sat Nov 16, 2019 9:16 am, edited 3 times in total.
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Re: "Parts Bike" a '77 rebuild thread

#5

Post by robbie202 »

my process is to break both bikes down to the frame and engine block then rebuild it back with a sleeker, tidier style, hop up the engine, and replace the electrical system with a modern german one.
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Last edited by robbie202 on Sat Nov 16, 2019 3:32 pm, edited 1 time in total.
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Re: "Parts Bike" a '77 rebuild thread

#6

Post by robbie202 »

the cylinder heads are obviously one of the main parts of the project. i was optimistic at first because under the valve cover they looked brand new! turns out they were damaged. the first valve i took apart had 2 keepers and the next valve had none. the tip of the cam was cracked from somebody struggling with the timing wheel, and one of the dowel pins was damaged under that cam rocker assembly thingy. all that together made me lose confidence in the head on that side so i just decided to use both from the other bike. they will go to the local machine shop for resurfacing later then after that i can rebuild it properly.
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Re: "Parts Bike" a '77 rebuild thread

#7

Post by robbie202 »

a lot of it is just cleaning.
i have no idea what these stamped numbers mean.
definitely want to freshen up those badges on the valve covers.
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Last edited by robbie202 on Sat Nov 16, 2019 7:54 am, edited 1 time in total.
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Re: "Parts Bike" a '77 rebuild thread

#8

Post by robbie202 »

lots of rust and corrosion on the spokes. sending the hubs and rims out for a rebuild.
i worked at a bicycle shop before so i know how to build wheels but i think i'll leave this one to the professionals.
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Last edited by robbie202 on Sat Nov 16, 2019 3:34 pm, edited 1 time in total.
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Re: "Parts Bike" a '77 rebuild thread

#9

Post by robbie202 »

i do ride with a passenger so i'm looking at a couple of options for the seat. Bought a triumph speed triple seat off ebay and didn't like it. the original 1977 seats are lost but i have one good metal base and one of the chrome grab bars. going to get this seat pan rebuilt as soon as i can figure out what this goo is. anybody know? i'm also going to try and make a fiberglass one that follows the lines of the frame. this fiberglass mold was a good first try. i'm mocking up out of cardboard to get an idea of what i might have the upholstery shop do later. fiberglass experiments on hold until warmer weather.
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Last edited by robbie202 on Sun Dec 22, 2019 11:05 am, edited 7 times in total.
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Re: "Parts Bike" a '77 rebuild thread

#10

Post by robbie202 »

anyway here it is in mock-up with the fake seat. this is as far as i got and that's probably it until at least spring break or maybe summer.
next couple of steps are to take it completely back apart then build the motor with the new electrics. progress will be slow i'll edit/update as i go.
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Last edited by robbie202 on Mon Dec 30, 2019 1:18 pm, edited 4 times in total.
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Re: "Parts Bike" a '77 rebuild thread

#11

Post by Fred Camper »

Oh my Robbie, lots of progress. Good plan. Have to decide how much Patenia to keep. More is better for my taste.
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1977 GL1000 BADDOG (April 2012 BOTM)
1976 LTD - '993 LTD...and so it begins'

You should remember that it's peace of mind you're after and not just fixing the machine. R.Pirsig
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Re: "Parts Bike" a '77 rebuild thread

#12

Post by robbie202 »

hey thanks Fred Camper. yes i love a good patina too. it tells a story. but this was definitely just grime and was interfering with the build. lots of simple green and elbow grease and i'll probably run most of these parts across the buffer. going to need to paint the engine and frame in spots.
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Re: "Parts Bike" a '77 rebuild thread

#13

Post by desertrefugee »

Following with great interest and patience. Nice plan of attack. Your photography leaves absolutely nothing to the imagination, I'll tell you that. Great work. Noble cause. And most importantly, on point with regard to the subject matter for this forum.

Unlike some of the rascals around here... :oops:

(And nice to see you back!)
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Re: "Parts Bike" a '77 rebuild thread

#14

Post by pidjones »

The goo looks like contact cement. I have a fiberglass seat pan on my '78. Looks like someone stripped a steel pan and used it as a form. Even has sockets for the rubber bumpers and nuts glassed in for the mounts. Made it real nice to build the new seat on. I'd try some various solvents on the goo - something is bound to cut it. Gasoline if all else fails (outdoors, of course).
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Re: "Parts Bike" a '77 rebuild thread

#15

Post by Fred Camper »

Like dissolves like, so gas outside may do the trick.
Proud member of the NGW Cartel (Rochester MI)
1977 GL1000 BADDOG (April 2012 BOTM)
1976 LTD - '993 LTD...and so it begins'

You should remember that it's peace of mind you're after and not just fixing the machine. R.Pirsig
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