'78 WR (OR?) Restoration

UHMW

That means ultra high molecular weight...

Tuff stuff

Ordered a block of it off ebay for $11.

Gotta sort out that reed box issues, but nice progress this weekend, fenders mounted, 40MM forks rebuilt and installed, rear wheel mounted. Went to mount front wheel and had to stop to sort out spacers and speedo drive. I'm using an '83 wheel, axle and spacer set up to accommodate the 40MM forks. My question is on the speedo drive - the one that was on the bike when I got it had a larger hole in the center such that the spacer passed all the way through. The nearly new one I sourced has a smaller hole in the center, just the width of the axle, that appears to get sandwiched between the axle spacer and right axle shoulder. I think the one that came with bike was modified, or incorrect to begin with, so just want to make sure that the correct speedo drive should be sandwiched instead of riding over the spacers. It all seems to line up and wheel centers using this method.

Tackled the seat last night. I had previously blasted and powder coated the seat pan. Foam was ok but had a few torn out spots that I patched with other foam:




You never know on the quality of seat covers, but I have had good luck with a guy out of Thailand, and for $35 I think it looks and fits great. I've done plenty of plastic seats and metal seats without glue, this was the first time using glue. I gotta hand it to Husky, they even give you upholstering instructions in the manual that are spot on. For those who have not done this, the key is to get contact cement on both the base and cover and make sure you let it set up before stretching and sticking it on. Just like OEM:

Nice job...OEM looking

excellent results..if I tried that the lines would be the other way for sure

What's old is new- new style seats have ribs for extra pleasure too.
Nice job Houred Oot

Just like the ones in the gas station vending machines!

I really like the thicker higher seat. I kind of stay put. The 80's to 84's seat is ok but I'm not comfortable with it. With the newer flatter narrow seats 1999 it's like stuck in my butt.lol I was standing up most of the time anyway.

Did you get the seat cover from an EBay seller? I got one from a guy awhile back but the back end was too short.
There was two styles of covers back then,one with the larger ribs like yours and one that looks like the ribs are embossed and don't go over the sides as much.
Nice job on the seat.

Yes, the guy is on ebay. I've bought covers for three different bikes and all were spot on.

Took a step back this weekend. Putting on the fenders and seat made me notice that the rear hoop is still not straight. I was all focused on the up/down the first time. Its level, but off to one side. When you look from the rear, fender does not line up with wheel. Should have done a mock-up prior to painting frame. I'm going to fabricate a bar to try and bend it, hopefully powder coat will flex.

Ive been putting off tackling the pipe, that dented spooge filled beast is next.

I tried a steel bar thru some u clamps to bend the hoop, but cant get leverage (bike just spins) and I fear I will kink the tube. I need to make a 90-degree tool and use some blocks with a contour to support the tube. F&*( this would have been so easy prior to PC, just slit the hoop at the weld seam, bend each rail over an inch and re-weld.

So I had to sacrifice a conduit bender, cutting off one side of it to clear the little tubes that hold on the seat, but it worked, no kinking of tubes and minimal damage to the powder coat. Fender and seat now line up properly when you look at back wheel. Now I can start moving forward again.

Am I ok mounting the right side like this, it just clears the airbox cover:

Both reservoirs will be mounted under the seat, but that requires a home made bracket that is in process. Meanwhile, I have a news flash: a headlight from a 35MM bike does not fit on the 40MM forks. Yes, you read it here.

I'm such a dumba$$ for not realizing this ahead of time, like before I put several hours into restoring a '78 headlight assembly. I don't want to just slap on a plastic headlight housing though, I want to come up with a way to make the old school metal headlight work with the 40 MM forks. Really like the way the original looks with the rubber clamps and grille on the light. Where is that DIY rubber molding kit when you need it? Ill be poring over options from other bikes, but if anyone has any ideas let me know.

The 'Street Fighter' guys strive for the minimal look and have many options. Some maybe food-for-thought.

For 40mm forks (with Rubber Inserts):

https://www.speedmotoco.com/cafe-racer-street-fighter-headlight-bracket-p/smc-.htm

Multiple options:

https://www.speedmotoco.com/headlight-brackets-cafe-racer-motorcycle-bracket-rat-bike-s/47.htm

Thanks! I wasted an hour checking out having the part 3D scanned, enlarged for the 40MM fork opening and then 3D printing the pattern to be molded in rubber. And then I came to my senses and clicked on the speedmotoco ones Vinskord found. Done.

I have a decent rider tank that I got from motomwo, but broke the bank on a beauty. Supposedly NOS, but who knows. Either way it looks new inside an out.