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Discussion Starter · #41 ·
I think you're right - my 82 parts book doesn't show the vent hose.

Worked on the dent with my buddy tonight and we're 90% there.

This gun welds steel pins to the dent. They have a small head like a finish nail.



Then he uses a slide hammer to pull on it. Here he's working on the little crease in the middle of the dent.



Here are the first batch of pins, he used them to get the dent 80% out in about 15 minutes!



After another hour or so, he got it 90% there. The pins were getting in the way of feeling the surface to find the low spots, so I'm going to grind them down. I also have to fill the hole where a pin pulled off.



I think it looks pretty good for a couple hours work, and when he's got some more time we'll get it to where it needs only a slight skim of bondo, if any.
 

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Discussion Starter · #42 ·
I ground down the pins, and brought it to my buddy's to weld the hole and finish the bodywork.



I got a little too aggressive with the grinder and thinned the metal too much. Kept chasing a pinhole with the welder so he decided to fill the area with lead. This is how it looks after we worked the low spots with a few more pins, and mostly with a rod from the inside. He was afraid the pins would burn thru thin spots, and it did once.



He offered to coat the whole area with lead next week because we couldn't get the surface flat enough for him. I also have to strip the tank to see what's under the bondo on the top.
 
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Discussion Starter · #44 ·
Started stripping many layers of paint off the tank. It'll look a lot better with just one layer.



Found another little dent to pull out



This is as far as I got with the first gorilla wheel. Need to get a couple more so I can do the rest of the tank and the fenders.

 

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Have considered having that tank (and the rest of the sheet metal) soda blasted? Unlike sanding or whatever you have used so far, blasting will get everything out of the nooks and crannys. Soda blasting makes little if any heat, perfect for sheetmetal. That old paint could very well cause issues in the future. Or not. You probably know better.

This place does a really good job on the interior portion of old gas tanks.
Interior Gas Tank Restoration
 

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Discussion Starter · #46 · (Edited)
Thanks for the link, but lucky for me, the inside of the tank is in good condition. There is no rust, sludge or previous coating. I will use POR-15 tank liner. I've done a car and two bikes with it, and never had a problem.

I just bought a bag of soda blast media and will be hitting the hard-to-reach areas with that. Thanks for that suggestion too @Turboprop the old paint definitely has to go.
 

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Discussion Starter · #47 ·
I will also lead the dents so I don’t have to worry about thin metal cracking or leaks. Meanwhile I sanded the paint off of both fenders.


270073


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I’m not real happy with the front fender, there is crash damage and rusty chrome. I would buy a good OEM fender if anyone has one. Vivid Black would be the most common, right?
 
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I'm a woodworker and I never would have used that random orbital FLAT sander on a rounded piece of wood. But I'm guessing on metal it won't leave streaked lines all over the surface? I would have done it all by hand with sanding sponges. Just a thought.
 

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Discussion Starter · #49 ·
I'm a woodworker and I never would have used that random orbital FLAT sander on a rounded piece of wood. But I'm guessing on metal it won't leave streaked lines all over the surface? I would have done it all by hand with sanding sponges. Just a thought.
Yes, there are lines, but it's not done yet. It is the fastest way to strip many layers of paint off metal.
 

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While waiting, I stripped down the gas tank and two fenders. I got new decals from Rick's Decals, and they look very original. Because this bike has been repainted, I'm not sure the decals are in the right place, but I measured them anyway. They are a little off from each other, so I'll adjust to what seems right.

View attachment 269947

View attachment 269948


Neither one is level on the bike, so I'll adjust so they are, or maybe tilt slightly up to the front?

View attachment 269949

View attachment 269950

Anyone have an original paint early FXR that can check if they are level or not?
Hi Joe. I am also currently restoring an 82 FXRS in CT. small world. I believe my tank paint is original. I measured the factory decal placement for you. Hope this is helpful. DD55EF6F-14F1-4ECC-83CA-16A0FD823C43_1_201_a.jpeg

pic 1 Right side vertical measurement starting point
pic 2. Right side vertical measurement
pic 3 Right side horizontal measurement starting point
pic 4. Right side horizontal measurement

pic 5 Left side vertical measurement starting point
pic 6. Left side vertical measurement
pic 7 Left side horizontal measurement starting point
pic 8. Left side horizontal measurement
270137
 

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Hi Joe. I am also currently restoring an 82 FXRS in CT. small world. I believe my tank paint is original. I measured the factory decal placement for you. Hope this is helpful. View attachment 270137

pic 1 Right side vertical measurement starting point
pic 2. Right side vertical measurement
pic 3 Right side horizontal measurement starting point
pic 4. Right side horizontal measurement

pic 5 Left side vertical measurement starting point
pic 6. Left side vertical measurement
pic 7 Left side horizontal measurement starting point
pic 8. Left side horizontal measurement
View attachment 270137
270138
 

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Discussion Starter · #56 · (Edited)
@sinderbloks Thank you for that! It'll help tremendously. It's interesting the horizontal measurements are not the same right and left sides.

ps, where in CT? I'm in Griswold, not far from the casinos.

[edit: I just noticed you have two gas caps - mine only has the one in the center. How far from center are your starting points?]
 

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Discussion Starter · #57 ·
Accomplished a few things in between working at my rental and enjoying summer. The humidity broke so I could paint the oil tank with the Majic Tractor Paint spray can. I also sanded the side covers and thought about the fender struts. I have to soda blast the bad one to get the crud off the inside, so that will wait until I can get to my friend's.







 
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@sinderbloks Thank you for that! It'll help tremendously. It's interesting the horizontal measurements are not the same right and left sides.

ps, where in CT? I'm in Griswold, not far from the casinos.

[edit: I just noticed you have two gas caps - mine only has the one in the center. How far from center are your starting points?]
its exactly 11.5" between my two measuring points on the gas caps.
|O O|
<--------->
so divide 11.5 by 2 and add that amount to each vertical measurement i made previously. then measure that new amount from the top center of your tank.

good luck !
 
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