Lowering the GL1000 - Page 9 - Steve Saunders Goldwing Forums

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post #81 of 187 (permalink) Old 01-03-2012, 06:58 AM
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keep up the great work.out here in ontario canada you do 1 safty and thats it.cars do smog every 2 years but not bikes.

1983 honda cb350 (gone)
1987 kz 125 (gone)
2003 polaris 330 4x4 (gone)
2009 1973 nonda cd175 (on the road)
2011 1985 honda goldwing gl1200(on the road)
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post #82 of 187 (permalink) Old 01-03-2012, 02:03 PM Thread Starter
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Monday 01/02/2012

I am not real happy with today's work, But I haven't figured out how to fix it yet.

I ground the welds down smooth on the rear fender tail light bracket and it looks OK except for the top rail.
It needs some fine sanding to get rid of the grain.



The spot on the top rail where the Honda logo goes was a little thin near the bolt holes and it kind of wore through
at the bottom where I had drilled to countersink the heads of the Allen bolts that hold the logo on.

I haven't tried but it may look better if I bolt the logo on, worse come to worse I could cut it off and make a new top.
I am still thinking.

After I messed up with the fender bracket I decided to go to something different.



I cut another 3 1/4 inch long piece of 1 1/4 inch channel iron to make the bottom fender bracket the same
as I made for the top fender and tail light mounting.

I drilled and tapped it out to 8 X 1.25 mm and welded it at the front bottom of the rear fender.



I still have to finish grinding it.

Then I sat down and thought about the fender bracket and listened to some old time country music, George Jones
always makes me feel better when I hear about some guy who got drunk, lost his job, his wife left him, and his pick-up won't run.

Golly I'm not so bad off after all, in fact I'm doing great.



1967-69 Vietnam Vet
Life Member DAV
Patriot Guard Rider

1996 GL1500 SE Trike
1980 GL1100 Naked and Low
(1) 1975 GL1000 (being lowered)
(5) 1975 - 79 GL1000 Parts bikes

"Never try to teach a pig to sing
It wastes your time and it annoys the pig."

"You can also follow me on my blog Zimco\'s Garage"


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post #83 of 187 (permalink) Old 01-06-2012, 08:52 AM Thread Starter
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Thursday 01/05/2011

I will start out with the fix for the fender & tail light bracket.

I cut two pieces of one inch flat stock on an angle to fit the top bar of the bracket. I clamped it with a pair of
vise grips just a bit lower than the top of the bracket.

The bottom of this then sits lower than the bottom of the top rail, that had the places that were ground out.



Aren't pictures great, what I can't explain become clear when you see the photos.



I then welded the sides and clamped the other side and did the same procedure to that.

My next objective is to grind the pieces to match the original top and side bars, so again it looks like one piece.
May be tomorrow I will get to that.

Something I never noticed on this bike was that someone along the line had destroyed the Back stand bracket.
They must not have been able to get the bolts loose or they didn't realize that the shaft holding it on had a
cotter pin through one end.
They cut the right side and bent the left side something terrible.



I came to the conclusion this needed to be fixed some how.
I went out to the shed and grabbed a frame from a 1978 that didn't have a good title and brought it into the garage.
I was going to scrap one of the frames anyway to make an
engine stand that I can use to check out the motors, so this will also be that frame.



I tipped the frame upside down and removed the stand from it. I was also going to remove the bracket from the
frame but after thinking about it I believe I will fix it a different way.



This brings us to a trick I learned from some where, it might have been on this site, but I can't remember.
Just in case I saw it somewhere else I will show you it here.

If you have to ever remove a spring from pins like that on a side or back stand stretch it out by moving the stand to the
position that pulls the spring to the maximum.
Then insert a screwdriver into one of the gaps in the spring.
Then push a penny into the gap you've created with the screwdriver.
Now skip one coil and do the same again.


It should look like this.

When you move the stand to the relaxed position the spring will basically falloff. No hard prying or broken knuckles.

My hat is off to who ever came up with this, it wasn't me, it is so useful in the shop.

After removing the spring, the stand came off very easy.

My fix on the hard tail frame is going to be to eliminate the clamps, weld large washers where the clamps were,
then make a new shaft that is slightly longer and hold it with a cotter pin.

Today I am off to "Herbs" a local bolt supplier that always has what ever I need in the way of fasteners.
What a great place seeing that Lowe's, Chase Pitkin, and Home depot have put all of our hardware stores out of business,
then they don't stock anything in the hardware department.
I might add that neither Lowe's, and Home depot has a good web site for searching, and Chase Pitkin is out of business.

I need to pick up some washers with a 3/4 inch inside hole to weld to the bracket. I also need some 8mm washers
for other bolts on the bike.





1967-69 Vietnam Vet
Life Member DAV
Patriot Guard Rider

1996 GL1500 SE Trike
1980 GL1100 Naked and Low
(1) 1975 GL1000 (being lowered)
(5) 1975 - 79 GL1000 Parts bikes

"Never try to teach a pig to sing
It wastes your time and it annoys the pig."

"You can also follow me on my blog Zimco\'s Garage"


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post #84 of 187 (permalink) Old 01-06-2012, 09:25 AM
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Now THAT is a good idea! My bleeding and sore knuckles are gonna thank you for that one some day.

1985 LTD.... 121,000 miles and counting

"Democracy is two wolves and a lamb voting on what to have for lunch. Liberty is a well-armed lamb contesting the vote." _ Ben Franklin

"Oops, that wasn't suppose to happen" _ Kevin (me)
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post #85 of 187 (permalink) Old 01-06-2012, 07:00 PM Thread Starter
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Friday 01/06/2011

First I have to tell you about the weather here in NY.
what normally is deep snow and cold here this year is
an occasional good day with the sun out.



The sunset through the garage window was bright red
so I had to go out and get a picture of it.

After going to Herb's and getting my washers I ground
down the rear fender bracket on top, and I think it looks
a lot better this way.



I next ground the old bracket for the back stand and
clamped a washer to it then welded it.



I did both sides of the bracket because I didn't like Honda's
design any way.
I have no idea why they thought they needed to put clamps
on the ends of the bracket instead of just having holes.



I did have to make a longer shaft and drill it for the pin.
I welded a washer to the left side of the shaft where the spring is
I had to grind a small groove on the washer to fit around the spring pin.
I also had to grind off the left end of the stand to make clearance for
the extra washer.

[img]">

The cotter pin on the end of the shaft will keep it from coming
apart so I think the clamps are over kill.



My bike will have the cotter key only.

Speaking of cotter keys, I see so many things with the cotter
pins bent wrong.
My high school shop teacher taught me to bend only the longer
end of the pin, and leave the other end straight.
You may cut the other end off a little if it hits anything if you want.

In a pinch this makes the pin useable again if you have to.
Also the pin comes out so much easier.

While I was working on the bottom end of the bike I decided to
change another item that I think Honda got wrong.



In order to lube the brake pedal you must remove it.
Why not put a grease fitting on it and lube it when ever you want.

I drilled the bottom of the pedal and tapped it to 1/4 X 28 threads.
When you do this the fitting will be slightly too long, so you will have
to grind the nipple off the threaded end.


Wire brush the end after you grind it and be careful when you first
thread it in to make sure you don't cross thread it.



Also look in the shaft hole to make sure it is clear and that you have
taken enough off of it.

It is a fairly simple job that will save you tons in the future.


1967-69 Vietnam Vet
Life Member DAV
Patriot Guard Rider

1996 GL1500 SE Trike
1980 GL1100 Naked and Low
(1) 1975 GL1000 (being lowered)
(5) 1975 - 79 GL1000 Parts bikes

"Never try to teach a pig to sing
It wastes your time and it annoys the pig."

"You can also follow me on my blog Zimco\'s Garage"


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post #86 of 187 (permalink) Old 01-08-2012, 07:09 PM Thread Starter
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Sunday 01/08/2011

I got thinking today, if a grease fitting is good for the brake pedal it would also be good for the back stand
which never gets lubricated the same as the brake pedal.



I welded a piece of round stock to the stand, drilled it, and tapped it for a fitting.



I also cut off the shaft for the stand so it wasn't too long.



The rest of the day was spent cleaning and arranging the garage. it had gotten to be such a mess in the last
few weeks I couldn't stand it.

I also removed the front forks, and took them apart.
I think I will use another set of forks because it looks like they might have gotten too hot near the fire.



1967-69 Vietnam Vet
Life Member DAV
Patriot Guard Rider

1996 GL1500 SE Trike
1980 GL1100 Naked and Low
(1) 1975 GL1000 (being lowered)
(5) 1975 - 79 GL1000 Parts bikes

"Never try to teach a pig to sing
It wastes your time and it annoys the pig."

"You can also follow me on my blog Zimco\'s Garage"


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post #87 of 187 (permalink) Old 01-10-2012, 06:43 PM Thread Starter
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Tuesday 01/10/2012

Well, today was the day to get my frame all gussied up, at least on one side.

I started by making a support by taking a slightly larger piece of tube and slotting it to fit around the frame. This goes where the old and new frame are joined on the bottom left side frame.

See Yellow arrow.



I then started to make the gussets.
see red arrow.



I spent the day cutting and grinding the pieces to fit on the rest of the new left side.



If I can work tomorrow I will flip the frame and do the right side.

I had to Quit early to get ready to go watch my Grandson Chuck play indoor football, tonight are the play-off games.



1967-69 Vietnam Vet
Life Member DAV
Patriot Guard Rider

1996 GL1500 SE Trike
1980 GL1100 Naked and Low
(1) 1975 GL1000 (being lowered)
(5) 1975 - 79 GL1000 Parts bikes

"Never try to teach a pig to sing
It wastes your time and it annoys the pig."

"You can also follow me on my blog Zimco\'s Garage"


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post #88 of 187 (permalink) Old 01-10-2012, 06:49 PM
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Uh-oh, that looks like the start of finishing work, do I smell the home-stretch comin'?

1985 LTD.... 121,000 miles and counting

"Democracy is two wolves and a lamb voting on what to have for lunch. Liberty is a well-armed lamb contesting the vote." _ Ben Franklin

"Oops, that wasn't suppose to happen" _ Kevin (me)
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post #89 of 187 (permalink) Old 01-10-2012, 06:54 PM Thread Starter
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Still a lot of work ahead, I am just hoping I get it done around spring.

1967-69 Vietnam Vet
Life Member DAV
Patriot Guard Rider

1996 GL1500 SE Trike
1980 GL1100 Naked and Low
(1) 1975 GL1000 (being lowered)
(5) 1975 - 79 GL1000 Parts bikes

"Never try to teach a pig to sing
It wastes your time and it annoys the pig."

"You can also follow me on my blog Zimco\'s Garage"


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post #90 of 187 (permalink) Old 01-11-2012, 12:11 AM
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I know, just tryin' to make ya feel better, I'm lookin' for that light at the end of the tunelfor my current"project" too,but hey, the back's almost done .

1985 LTD.... 121,000 miles and counting

"Democracy is two wolves and a lamb voting on what to have for lunch. Liberty is a well-armed lamb contesting the vote." _ Ben Franklin

"Oops, that wasn't suppose to happen" _ Kevin (me)
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