RG - Extensive clean

[Arronduke]

The painting has started, the motor parts have been washed and cleaned with prepsol to remove all traces of oils and grease.
I like to warm the paint can and the thing to be painted.



And the paint for the crank cases, very very close to factory, I tried a test piece and was happy with the result. The covers use a higher gloss paint.
To add the reputation of Dupi.cololr and I was happy to use it. Low Gloss DE1634

Good quality masking tape and a scalpel is useful, cant imagine doing it another way.




ready to paint.


The moment... need to be relaxed... 3 coats, 2 light 10min apart and one heavy coat to finish. Spray can has been warmed, thing to be painted warmed, wives car close, don't care ready to go.



looking good, I love that there is a 10min wait between coats.. ample time to relax and have a beer.

[Arronduke]

Righty Ho some more painting.

[Pumba]

Righty Ho some more painting.

Fuck bro. How many USB cables do you own?

[Arronduke]

The painting goes on... all the engine casing parts but not the outer covers, they are a higher gloss paint.

Its going to take some masking for the upper engine block, it been cleaned twice with a hose, every hole blown out with compressed air. Yep its clean.
Mean while the heads are done, everyone like a good head job and I was not disappointed, it felt good. Nothing like a good head job to get the blood flowing.

[sugilite:Me]

Looking good! Great work!

[Cheesy]

Is that paint ok to use on bare aluminium without the primer?

[Arronduke]

Is that paint ok to use on bare aluminium without the primer?

According to the instructions yes.

Quoted by RG owner from the UK website, whom I have found out know more than I do... yes hard to believe, wife did not think it was possible but this lot know their shit.

yamagamma, on 31 Jul 2015 - 09:13 AM, said:
Dupli Color Engine Enamel Low Gloss Black DE 1634 is a very close match to the factory crankcase paint. The covers are slightly glossier. I did the stator cover, Cluch cover and the chain cover in Dupli Color regular Gloss black engine enamel and it looks very factory. No primer neccessary, just beadblast, wash thoroughly, and paint. I've used this stuff on of my race bikes and it holds up really well.

[Arronduke]

You have to love masking tape.. and I do. It has so many uses. While its not as good as duct tape which we all have to agree is the second best invention next to cable ties. The good old masking tape can still render someone immobile....

You have to have a love with masking tape.... what an effort. Shit it was hard to work out what was more expensive.... the beer or masking tape cause this took f#cken ages..











Ready to paint.... and I have an oven all set up to cure everything.! Been then there and done that..... use the oven inside, about 4pm on a Sunday... fatal mistake. House stuck for hours and wifey was not happy when it can to cook dinner an hour later... the whole house stunk..!

[ruaphu]

Yeah awesome job on the prep work, looks sweet once all done.

Re the oven, yeah i done the very same thing a few years back too when rebuilding the CBR. I was about as popular as blood puddin at vegan convention for a few days

Great thread man, been a good read thus far, keep the installments comin.

Cheers Ando


Sent from my iPhone using Tapatalk

[Arronduke]

Ruaphu, thanks for the great reply.

The build is coming along very slowly, as money can be found.

Painted, dam thing nearly fell over. That would have ripped my undies but true black cap style I caught it just in time.
Reason.... swinging it off different wires to paint underneath etc, once I worked that out it was good to go.




F#ck me not a beer in sight.... must be a Monday.

The finished piece, just needs to sit for a week and off to the bake oven.


Holly shit... I just realised that's fruit in my picture, what is this doing to my image? Wife is thinking after seeing an RG for 20K on trade me she wants to keep me alive long enough to finish the bloody thing. Bitch actually asked me if I could remember how to put it back together! "As long as my ass points to the ground and my knob can point to the sky I thing I can pull it off". "So yes!"

[Mike.Gayner]

Loving this thread. Keep it coming.

[Arronduke]

Right I have to deal with the heads and the studs....something I though I had better ask the wife about as she being dealing with this problem for 15 years...
Her advise was to add some heat, tighten the nuts and screw it.... out.

Not going to argue here...

Nuts are in place and tightened... now just need some of the wife's leverage and pulling on the lower nut... and that stud is deflated and in to a snap lock bag.... a heat gun is great here and in the end I did not even use that. All studs where removed with little effort. No special tool was needed here. My plan old nuts did the job.



Getting ready to send the cylinders of to be bored +.5mm with original Suzuki pistons.

And for the people thinking what the hell, the man is losing it... not a beer to be seen. Well you are correct, I got sick of cleaning bottles and tiding up in my shed. Some thing had to give so I found a high power. Yep anyone else that would like to improve themselves and forget about the bottle I can help. Its a journey well worth taking...

Its called KEGS... homebrew on tape.

[Arronduke]

Here is an interesting question.... we all want to build our engines cheap, why spend a cent more than we have to spend, especially after I have worked out that 9/10 times you will never get your money back. Look up KX250 build to see what I mean. Its about the enjoyment of solving a mystery, a jigsaw puzzle, fighting your demons and proving every other fuKker wrong. Like cooking and yes I am a good cook, its as simple as reading a book. But yes I have made heaps of mistakes, I used to rebuild a FULLY worked RZ350 motor for a RD350LC frame in my twenties, I even brought a JMC swingarm and a Nos kit for it!. And that was some time ago. Walk to the shed in the back of the section, beer'S in hand, small garden shed nothing flash. Big enough to hold a work bench, a stereo and my chair. Rest of the bike was in the car port. A bigger shed was on order... like a larger garden shed, a garage was only a dream. Long story short first 30mins was spent fixing yesterdays work after being to pissed to do it properly and the second 30min was spent attaching bits in the wrong place, all before heading to the pub. But I tell you what that engine ran real good when it was finished. I have a picture somewhere but talk about shame on the paint job.

If short of time skip to here... after market gasket set sourced. After spending some serious and we are talking serious amount of cash rebuilding this thing why would you not buy everything original? One badly sourced part could destroy this engine. I don't want to even ask what it cost to rebuild an RG5 engine, casue I'm not counting. All I know is that the wife's keeps asking why we don't have any savings. All I can say is Fukc me but I have no idea, did you buy your lunch today? well its about leakage and the coffee here, bit of Mac D there and were broke.

Really bored.... start here!!!After market gasket and o-ring kit, from Italy like many of the other parts I have used. They ONLY specialise in RG500. Their parts work....I hope.








Discussion on after market parts... basically only use OEM unless the after market parts are 100% proven. I have the piece of mind of such. Any after market part has to be proven and identical replacement another one I often use is seal from seal house, but not this time. Bearings yes, but plan ones only, O-rings (in kit above) yes but not gaskets and seals. ALL OEM

[sugilite:Me]

I reckon your taking the right approach with OEM vs Aftermarket. You can only do what you can do at the end of the day. The quality of those gaskets and seals look right up to the job to me. Good luck with it all

[Arronduke]

received some good advise today, I thought I would post it so I actually did what was recommend.

I think a lot of the "problems" people have with gasket's is that they don't prep the surfaces or tighten to the right torque setting, make sure that all of the bolt holes have a nice radius, make sure the threads on the bolts/studs are clean other wise torque settings go out the window.

To be honest on any 2 stroke head bolt's/barrel nut's i don't use a torque wrench, you can "feel" when it's tight enough (20ftlb most is max),and make sure you use the right tool's, you don't use a 1/2" socket wrench for 8mm threads!

Also pay's to check the barrels on a 2 piece setup twin are sat at the same height with a straight edge and put the head on a bit of plate glass make sure it has no gap's with a feeler blade.