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Project GT250 Fun and games!!!!!!!!!!

Discussion in 'Your 250cc Projects' started by Damian_74, Oct 20, 2019.

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  1. Damian_74

    Damian_74 Well-Known Member

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    New work bench finished - completely over-engineered but happy with the result!

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    Even Little Miss approves!
     
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    Damian_74, Oct 20, 2019
    #21
  2. Damian_74

    Damian_74 Well-Known Member

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    Fork legs back form Rad Hard Chroming, won't say that it was cheap at $420 AUD (straighten and rechrome) but perfect job.
    In comparison the new pattern fork legs that I bought for by GT250 74L were about the same after shipping - in chatting with the bloke at Rad, his reply was that his chrome will be thicker and last longer - as I can't see either bike doing 1000's and 1000's of kms and definitely not parked in the weather so I don't think it really matters.

    So that took me back to my favourite job - polishing - MORE MESS!!!!!!

    I thought that I would try Walnut Shells in my blast cabinet - didn't work so well continually blocking the syphon tube - tried different air pressures and nozzle sizes but nothing seemed to work. Looking on line at different sites and was thinking of fitting a metering valve in place of the syphon tube gun.......so for the interim I used glass beads. As a prep to polishing it took a lot of the hard work out - removed the factory lacquer and cleaned all the impossible corners.

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    Damian_74, Oct 20, 2019
    #22
  3. kiffsta

    kiffsta Senior Member

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    A couple of great projects there Damian, I have a t500 that I ride and a Gt380 project on go, look forward to meeting up for. 2 stroke
    Ride
     
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    kiffsta, Oct 20, 2019
    #23
  4. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    Welcome to the forum.
    Nice bikes and well equipt workshop and knowledge to use.
     
    Murdo, Oct 20, 2019
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  5. risky

    risky risky

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    envious
     
    risky, Oct 20, 2019
    #25
  6. Damian_74

    Damian_74 Well-Known Member

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    Thanks for the welcome Gents - will post updates but don't hold your breath - as we all know these things take time and money, both usually on short supply. Just as well I have other bikes to ride!
     
    Damian_74, Oct 20, 2019
    #26
  7. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    :welcome:
     
    Andych, Oct 21, 2019
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  8. Damian_74

    Damian_74 Well-Known Member

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    Working on a better dust extraction system for my blast cabinet - now have two cyclones in series fitted up with a cheap ALDI vacuum (on sale for $40 this week) . the primary stage catches 95% of the dust, the 2nd stage just has a slight dust layer - the inlet hose to the vacuum is completely clean!

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    I turned up some aluminium sleeves - everything just slips together and held in with clamps - no taping or gaskets needed!

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    Necked down the bearing area on the head-stock spindle so that I can use taper roller bearings rather than the antiquated ball bearings that Suzuki use.

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    So with the sandblaster back in operation - started on all the small odds and ends - blasted with crushed glass and etch primed.

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    Damian_74, Oct 21, 2019
    #28
  9. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    Great idea. Where did you get the cyclones?
     
    Murdo, Oct 22, 2019
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  10. Damian_74

    Damian_74 Well-Known Member

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    Damian_74, Oct 22, 2019
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  11. Damian_74

    Damian_74 Well-Known Member

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    Did about an hour blasting with the new extraction system - I might call it a success.
    First stage catches just about all of it, with the 2nd stage just taking out some of the fines.
    There was a slight dusting in the inside of the duct pipe into the vacuum but nothing detectable in the vacuum filter.

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    Joys of blasting - can see what you are getting into - if anyone has a spare Suzuki GT250 A, B or C air box about, please let me know before I spend countless hours repairing this one.

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    Damian_74, Oct 23, 2019
    #31
  12. kiffsta

    kiffsta Senior Member

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    try netbikes.com.au

    chris might have one @netbikes
     
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    kiffsta, Oct 23, 2019
    #32
  13. Damian_74

    Damian_74 Well-Known Member

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    Picked up my frame and bits form the powder coaters - $360, fairly happy with that, quality work. All the treads and bushings taped.

    Like a Kid at Christmas, just had to unwrap it.

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    NOW WE CAN START THE FUN BIT!!!!!!!!!!!!

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    Damian_74, Oct 25, 2019
    #33
  14. Damian_74

    Damian_74 Well-Known Member

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    Progress has slowed - time and money, both in short supply!

    Forks rebuilt with re-chromed legs and new seals.

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    I'd wasted many hours on the internet attempting to find out what was correct for the bike regarding the headlight brackets and housing - Chrome vs tank colour vs painted black - gave up in the end and just powdercoated everything at the same time as the frame. When I picked up the bike it was all rusty painted black so I have to assume that is how it was delivered back in the 70's.
    After many more hours on eBay I ended up finding two NOS headlight brackets and affordable prices - for some strange reason there are almost no left hand ones available - I can only assume that the bike falls on that side more often with its dodgy side stand????

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    Caliper sand blasted and painted with High Temp. rattle-can black. Used a rebuild kit form Cruzinimage. The piston and seals fitted perfectly but couldn't assemble the two half's with the supplied O rings on the bolts. Even after machining a gentle lead on the bushings the O rings wouldn't sit in place and ended up cutting them. Replaced the O rings with some I had in a grab kit - Viton 10mm x 1.5mm - worked perfectly!

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    Damian_74, Nov 16, 2019
    #34
  15. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    FKM (Viton) should not be used with brake fluid. You need EPDM.
     
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    maelstrom, Nov 16, 2019
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  16. Damian_74

    Damian_74 Well-Known Member

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    The O rings aren't in contact with the brake fluid - it is on the mounting bolts greased with rubber grease.
     
    Damian_74, Nov 16, 2019
    #36
  17. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Ooops my bad, carry on :)
     
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    maelstrom, Nov 16, 2019
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  18. kiffsta

    kiffsta Senior Member

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    Having the same issue on the gt380 with oem seals , was going to seek help from a mate who is an ex Suzuki tech
     
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    kiffsta, Nov 16, 2019
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  19. Damian_74

    Damian_74 Well-Known Member

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    Damian_74, Nov 17, 2019
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  20. Miguelone

    Miguelone Member

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    Awesome stuff, love all the diy shop ingenuity
     
    Miguelone, Nov 18, 2019
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