Project 72 Honda SL125

Ordered a replacement muffler and header pipe today from Musket Mufflers in NZ.
Replica items built to factory specs. Design copied from a NOS full exhaust.
My old header pipe is made of 4 different sections and the muffler is like aluminum foil so it wasn’t a tough decision to replace it all


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The whole backside of the muffler is gone on mine... well thin enough that it is almost impossible to repair. Given the extent I have gone to, a new Muffler and header pipe is a logical step.

You are possibly correct in your assumption but another contributing factor could well be that most people (and I am guilty of it on both my original SL100 and my new at the time SL125) is removing the baffle in the end of the muffler.
This allowed the exhaust to flow better and if memory seves correctly run a bit cooler... all contributing factors most likely.
I can see on my old one where someone has put a drainage hole in the bottom of the muffler, might be from factory even... but they just tend to be a point where rust first starts rather than an effective drainage hole...
Either way a new muffler will go a long way towards completing the bike... I still need to polish up the chrome grille from the old exhaust (I would get it re-chromed but cant wait the 3 months they have quoted me... lol) and find the foot protector plate that bolts on down near the rear brake pedal. They are almost as hard to get as the chrome grille.

 

Finally a full weekend where I can get some painting done...
I decided that as I am painting the tank I would deploy my fold up Paint booth.... a few years ago (not sure how many now) I bought a JFlex paint tent... it took a while to figure out how it went together but it worked well...



The last couple of weekends or parts thereof I had been repairing, filling, sanding, priming, filling some more, sanding some more... well you get the drift this Honda 50+ year old tank to a state I was ok with.
It was final primer coated during the week and prepped for paint this morning. Set up in the "booth" ready to go.


First couple of coats of silver.... It is hard to see the proper colour with it being so bright.



All done with Rattle Cans... my preference is DNA Paints and it just goes on so easy.


Silver is all done... Masked up for the Black stripe down the middle and first couple of coats of Pure Black...


All the masking removed... now to leave it overnight. I have a small issue to correct in the morning... my masking near the tank filler wasnt the best so I need to mask the black and blend in some Silver... shouldnt be a big issue.
this Pure black by DNA is amazing in the way it goes down... a wonderful ground coat.



I couldnt help myself...I had to tape up one of the decals just to see it against the tank...
I found a website that has all the measurements of where to position the decals... all using an original tank and showing the where the measurements were taken... very helpful.

 

Sorted out the small overspray and then left it all out in the sun to harden up.
Gave it all a light wet sand to flatten it off and set about the decals on the first side.
So far I am pretty happy with how it is coming together



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This will be 2K Clear coated. It was really just to take the sharpness off the edge of the black strip down the middle.
All the paint including the clear is from DNA paints so I am following their recommendations.


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I am hoping to get all the paintwork done next weekend... maybe...
Depends on if we are able to get tickets to Panthers / Storm GF... another week wont hurt

 

Finished putting decals on the tank... safest place to store the tank is on the bike.

 

After a week in Brisbane for work and then a long weekend in Sydney for the grand Final it was nice to have a good day to blast on some Clear Coat.
No rattle cans this time, using DNA Custom Clear with a medium speed hardener.
Set up my Spray Tent again


Then played down the first of 4 coats







Gave them a couple of hours cooking in the tent away from flies and other crap in the air.
Then put them in the shed to harden.
I need to sand out a run, well more of a slump than a run on the underside of the tank. Easy to fix once it’s hard enough.
May need another finish coat but I will see.







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It has been pretty busy since my last post on the SL125.
Managed to get all the wiring sorted. The Indonesian harness was missing some double connectors and colors were a bit off but worked it all out.
I couldn’t figure out why the headlight was a bit dim until I found out it was a 12 volt unit lol.
New 6 volt on order now.



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I wasn’t happy with the finish after sanding out a couple of minor runs and then wet sanding prior to buffing.
It just wasn’t coming up as glossy as I wanted so a light 600 grit wet sand and another coat of clear.
Also re- cleared the front guard as the crap from a rattle can I did previously didn’t harden correctly.
I just love the finish straight off the gun with the DNA Custom Clear.





I was very lucky as well. Just finished cleaning the gun and moved both items back into the shed to dry and it started to rain.
Thankfully humidity is still low 50’s.


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Chrome muffler guard beginning its soak in evaporust. These are either unobtainable or super expensive so will see how this comes out.
There is a little bit of damage which of course can be filled and finished then re-chromed but I want to see how it looks cleaned and polished first



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Well this may be my last post on this particular thread.... I posted her up for sale on FB Marketplace (in the appropriate groups) and had about 10 people all syat they were interested but only one asked for my number and called me... we basically did the deal on the phone there and then.
He is comeing tomorrow for the final inspection and he will try to negotiate down...but I have 3 other people who have given me their number and said if "old mate" tomorrow doesnt take it... they will. So I wont be dropping my price at all.
There are also 2 50 litre tubs of parts etc.
Final pics after she was wheeled out into the sunshine and down to the main garage waiting to go to a new home.