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Posted (edited)

So we've been riding since we were a kid - oh gods it's been 25 years - and in all that time we've never owned anything bigger than a 250. But then our daughter discovered the existence of touring bikes and shoved her iPhone in our face with a picture of a Goldwing on it, demanding to know why she "has to hang on for dear life" on our Puch when she could have been comfy and luxuriating in a world of armrests and cupholders. But like hell we're going to end up on a Goldwing, and we prefer vintage bikes so after a bit of looking we decided on a Venture. Then, as is our usual MO, we did not do sufficient research and bought the first one we liked. Which was this particular '83:

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After a week of riding it around and poking and prodding at things reality started to set in and we realized that setting this beast straight is going to take a lot of work. In no particular order we've already identified the following issues:

  1. The water pump is weak, leaks coolant through the weep hole, and it runs very hot, particularly when sitting in traffic.
  2. The plastic bodywork is not in great shape - there's several pieces missing, cracks & broken off tabs all over the place, and it's partially held together with zip ties.
  3. The anti-dive system on the front brakes is disconnected.
  4. The air suspension system is non-functional.
  5. The headlight is very dim.
  6. The CMS is throwing a battery warning despite the battery / alternator appearing to be fine.
  7. The speedometer reads about 15% faster than actual speed per GPS.
  8. The left side of the dash is shattered and the previous owner just screwed a solid plate of ABS over it, rendering the coolant overflow canister inaccessible.
  9. The lock over the gas cap is broken and opens with a screwdriver.
  10. Second gear currently works fine, but it's got 40k miles on it and there's no evidence that the faulty split-washer's been replaced. So that's looming.
  11. The cassette player's missing and has been bypassed.
  12. The left rear turn signal is held together with duct tape.
  13. The forks make a clunking sound when going over bumps.

#1 appears to be the plastic impeller issue, and we've already ordered the parts to deal with that. We're going to reflow the solder on the CMS to hopefully deal with #5 and #6. From what we can tell on #10 it may be more economical to just swap in a 1300 from the 2nd gen when and if it starts popping out of gear. #13 is apparently normal on 83's? The previous owner threw in a set of 2nd gen shocks so it might be worth it to try and swap those in if they're interchangeable. Don't think there's much we can do about #7 since it's cable-driven. Most of the rest are just a matter of hunting down replacement parts, but we're going to need help with #3 and #4 - we don't know how much of those systems are missing and what's broken or how to set it straight.

So yeah, we appear to have landed ourself yet another Project 😅. At least we're wrapping up things on the Puch. Wouldn't want to get bored, after all.

Bonus pics of the two next to each other. The Venture sure makes the Puch feel tiny as all hell!

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Edited by HeatherFeather
  • Like 2
Posted

Read this thread before you jump in deep. There are other threads here on the same subject. Most of your list isn’t terrible to fix. Unfortunately the 2nd gear issue along with the frame makes the 83-85s a little less desirable. Hopefully the 1st gen guys will be along shortly. @skydoc_17 @Marcarl @saddlebum

plastic parts are getting really hard to find in decent shape. 

Posted
6 hours ago, HeatherFeather said:

So we've been riding since we were a kid - oh gods it's been 25 years - and in all that time we've never owned anything bigger than a 250. But then our daughter discovered the existence of touring bikes and shoved her iPhone in our face with a picture of a Goldwing on it, demanding to know why she "has to hang on for dear life" on our Puch when she could have been comfy and luxuriating in a world of armrests and cupholders. But like hell we're going to end up on a Goldwing, and we prefer vintage bikes so after a bit of looking we decided on a Venture. Then, as is our usual MO, we did not do sufficient research and bought the first one we liked. Which was this particular '83:

spacer.png

After a week of riding it around and poking and prodding at things reality started to set in and we realized that setting this beast straight is going to take a lot of work. In no particular order we've already identified the following issues:

  1. The water pump is weak, leaks coolant through the weep hole, and it runs very hot, particularly when sitting in traffic.
    You've got that covered seems like. There is a direction valve at the bottom of the rad, below the rad that needs to be set in the off position, check that.
  2. The plastic bodywork is not in great shape - there's several pieces missing, cracks & broken off tabs all over the place, and it's partially held together with zip ties.
    Yep, you get to practise making and fixing, winter time off season project, but can be done.
  3. The anti-dive system on the front brakes is disconnected.
    Most likely has progressive springs or equivalent, then anti dive is not needed
  4. The air suspension system is non-functional.
    Only works in acc mode on the key. Probably will need to be re-soldered at the controller for a start.
  5. The headlight is very dim.
    That's normal, Put in a brighter bulb such as a Silver Star and add decent driving lights.
  6. The CMS is throwing a battery warning despite the battery / alternator appearing to be fine.
    In the battery compartment there was a wire with a probe on the end that was stuck into a hole in the battery. If it's still there cut off the end,  only the probe, and install a ring connector to fasten it to the positive post. Check to make sure that the resistor is still in place or you will fry the computer.
  7. The speedometer reads about 15% faster than actual speed per GPS.
    Time to grease the cable and clock, you should be able to find the procedure on this site.
  8. The left side of the dash is shattered and the previous owner just screwed a solid plate of ABS over it, rendering the coolant overflow canister inaccessible.
    That would be the right side, but no matter, that makes it a pain, Maybe look for one you can repair.
  9. The lock over the gas cap is broken and opens with a screwdriver.
    Happens.
  10. Second gear currently works fine, but it's got 40k miles on it and there's no evidence that the faulty split-washer's been replaced. So that's looming.
    Not sure a second gen will fit, but an 85 will. If you can find the right numbers, halfway thru 85 they fixed the issue.
  11. The cassette player's missing and has been bypassed.
    Nice, no need to deal with that pain then.
  12. The left rear turn signal is held together with duct tape.
    Might be able to use Plastifix to repair. Get the big kit, you'll need it. Or find a replacement.
  13. The forks make a clunking sound when going over bumps.
    Could be shortage of oil, or maybe somebody screwed up previously.
    Also check the frame, mid section, some have had rotting problems there.

#1 appears to be the plastic impeller issue, and we've already ordered the parts to deal with that. We're going to reflow the solder on the CMS to hopefully deal with #5 and #6. From what we can tell on #10 it may be more economical to just swap in a 1300 from the 2nd gen when and if it starts popping out of gear. #13 is apparently normal on 83's? The previous owner threw in a set of 2nd gen shocks so it might be worth it to try and swap those in if they're interchangeable. Don't think there's much we can do about #7 since it's cable-driven. Most of the rest are just a matter of hunting down replacement parts, but we're going to need help with #3 and #4 - we don't know how much of those systems are missing and what's broken or how to set it straight.

So yeah, we appear to have landed ourself yet another Project 😅. At least we're wrapping up things on the Puch. Wouldn't want to get bored, after all.

Bonus pics of the two next to each other. The Venture sure makes the Puch feel tiny as all hell!

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  • Like 1
Posted

Welcome!  My favorite color!

We used to have a member contributor (Cowpuc) who is a legend on this site who only rode 83s and 84s and he and his wife rode them all over the country.  If you can find his posts of his adventures they are quite entertaining.  

Posted

If you can get it up on the center stand without help, the frame isn't broken, yet. Carl covered everything else quite well.

Losing second gear really isn't that big of a deal. Not optimal, obviously but it's easy enough to just skip second on the fly.

If she's running on all four cylinders, idles smooth and accelerates like a scalded dog, excepting the broken frame possibility, she's a keeper.

Posted
19 hours ago, HeatherFeather said:

So we've been riding since we were a kid - oh gods it's been 25 years - and in all that time we've never owned anything bigger than a 250. But then our daughter discovered the existence of touring bikes and shoved her iPhone in our face with a picture of a Goldwing on it, demanding to know why she "has to hang on for dear life" on our Puch when she could have been comfy and luxuriating in a world of armrests and cupholders. But like hell we're going to end up on a Goldwing, and we prefer vintage bikes so after a bit of looking we decided on a Venture. Then, as is our usual MO, we did not do sufficient research and bought the first one we liked. Which was this particular '83:

spacer.png

 

This is the bike that enamored me to the Venture.  I was 17 when they first came out and a friend getting ready to go into the Army decided he was going to buy one. Going to the dealer he took it on a test ride and bought it. I rode it the next day and was able to ride a wheelie in 3rd gear. I fell in love with that bike.  He had it for abut 4 years and I wish I would have bought it off him, just couldn't afford it. I did get to own a gen 2 and now own a gen 3.  If the frame is not an issue, I think you're going to have a lot of fun with this bike. 

Posted
6 hours ago, luvmy40 said:

If you can get it up on the center stand without help, the frame isn't broken, yet. Carl covered everything else quite well.

Losing second gear really isn't that big of a deal. Not optimal, obviously but it's easy enough to just skip second on the fly.

If she's running on all four cylinders, idles smooth and accelerates like a scalded dog, excepting the broken frame possibility, she's a keeper.

We got her up on the center stand, though we did need some help seeing as how we're a fairly small woman and don't weigh enough to lever it up there lol. But the frame looks good at least - from what we can see there's not any noticeable rot or rust. Definitely nothing broken. And she definitely runs smooth as all hell, that was honestly the reason we overlooked everything else at first; our first test ride put such a big smile on our face that we couldn't resist.

@Marcarl: Followed your suggestion on problem #6 and that's sorted now! She's no longer throwing any errors so we can finally peel off the piece of electrical tape the previous owner stuck over the warning light lol. We also managed to find the missing dash chunks down in the fairing and glued them back together so the right side of the dash is at least reassembled, even if it's not in the best shape. As for #4, the screen does light up when the key's on acc, but all the buttons are unresponsive. We'll reflow the solder on the board and see if that helps.

16 hours ago, BlueSky said:

Welcome!  My favorite color!

We used to have a member contributor (Cowpuc) who is a legend on this site who only rode 83s and 84s and he and his wife rode them all over the country.  If you can find his posts of his adventures they are quite entertaining.  

Don't get too attached - we're planning on stripping off the plastics, fixing them up and repainting as a winter project. Definitely not going to keep it gold - we're leaning towards a matte pastel pink at this point.

  • Haha 1
Posted
9 hours ago, HeatherFeather said:

Don't get too attached - we're planning on stripping off the plastics, fixing them up and repainting as a winter project. Definitely not going to keep it gold - we're leaning towards a matte pastel pink at this point.

Oh noooo. Don't know how she will react to that,,,,,,,,,you're stepping out into some real new territory. LOL

 

  • Haha 1
Posted
16 hours ago, HeatherFeather said:

We got her up on the center stand, though we did need some help seeing as how we're a fairly small woman and don't weigh enough to lever it up there lol. But the frame looks good at least - from what we can see there's not any noticeable rot or rust. Definitely nothing broken. And she definitely runs smooth as all hell, that was honestly the reason we overlooked everything else at first; our first test ride put such a big smile on our face that we couldn't resist.

@Marcarl: Followed your suggestion on problem #6 and that's sorted now! She's no longer throwing any errors so we can finally peel off the piece of electrical tape the previous owner stuck over the warning light lol. We also managed to find the missing dash chunks down in the fairing and glued them back together so the right side of the dash is at least reassembled, even if it's not in the best shape. As for #4, the screen does light up when the key's on acc, but all the buttons are unresponsive. We'll reflow the solder on the board and see if that helps.

Don't get too attached - we're planning on stripping off the plastics, fixing them up and repainting as a winter project. Definitely not going to keep it gold - we're leaning towards a matte pastel pink at this point.

Unfortunately, the frame rot is all internal until it breaks. Odds are it's OK though.

I've brought 2 CLASS modules back to life by re-soldering the pins on the board.

I seem to recall seeing a Hello Kitty themed Venture at one point. Not sure if it was here or elsewhere.

Posted

It would appear you have a well maintained example of an '83.  I do note that you have an '86- and up front end with the electric anti-dive system.The clutch cover with the intact lettering suggests you have a keeper.  Its just beautiful. As for the "clunking" in the front end,, that may be the result of incorrectly set steering neck bearings.  You should lift the front wheel  off the ground while you have it on the center stand and check for slop in the front end.

E-bay is your friend.  Most parts, with the exception of the ignition system and the rear brake master cylinder, are usually available, eventually, if you keep your eye peeled.  I'm a fan of the gold of the original but that's not important.  Epoxy and fiberglass will fix 95% of the plastic issues. 

Another fine fix you may have in your upgraded front forks might be the bleed nipple up by the hazard light switch.  Hopefully you have one there.

To add detail to the Cow Puc or Puc Puc comments, he bought Ventures with bad second gears for short money and then, without fixing the second gear, ran the bike out to 200,000 miles.  He did this several times and did over half a million miles on these no second gear bikes.

I will share a pic of mine.

Venture83.jpg

Posted

Oh yeah, a quick note, after examining your photos, I note that your right front engine guard is way too close to the plastic elbow that supplies coolant to the pump.  As the engine is rubber mounted, it can vibrate against this pipe elbow and cut a notch in it.  Bend it out so there is some clearance between the pipe and the engine guard.

Posted
On 8/3/2024 at 6:15 PM, Vickersguy said:

Oh yeah, a quick note, after examining your photos, I note that your right front engine guard is way too close to the plastic elbow that supplies coolant to the pump.  As the engine is rubber mounted, it can vibrate against this pipe elbow and cut a notch in it.  Bend it out so there is some clearance between the pipe and the engine guard.

Done! The existing pipe had a notch already dented in it from the guard, so it's bent back out of the way and we ordered a new pipe with all the water pump stuff. Can't get the Venture ones new anymore, but it turns out the equivalent part on the V-MAX 1200 is identical aside from being black, and it's still in production.

On 8/3/2024 at 6:00 PM, Vickersguy said:

By the way, your Puch is stunning !

Thank you! It's a 1967 Puch 250 SG/S - the only split-single bike ever sold in the US. It still needs a little work done - the shocks are shot, the carb's pretty worn out, and we need to replace the front brake lever with the correct Magura lever - but it's overall very solid. We rode it up to the top of Mount Blue Sky, the highest paved road in North America at 14,130', this summer and back home to Aurora and it didn't miss a beat!

On 8/3/2024 at 5:51 PM, Vickersguy said:

It would appear you have a well maintained example of an '83.  I do note that you have an '86- and up front end with the electric anti-dive system.The clutch cover with the intact lettering suggests you have a keeper.  Its just beautiful. As for the "clunking" in the front end,, that may be the result of incorrectly set steering neck bearings.  You should lift the front wheel  off the ground while you have it on the center stand and check for slop in the front end.

E-bay is your friend.  Most parts, with the exception of the ignition system and the rear brake master cylinder, are usually available, eventually, if you keep your eye peeled.  I'm a fan of the gold of the original but that's not important.  Epoxy and fiberglass will fix 95% of the plastic issues. 

Another fine fix you may have in your upgraded front forks might be the bleed nipple up by the hazard light switch.  Hopefully you have one there.

To add detail to the Cow Puc or Puc Puc comments, he bought Ventures with bad second gears for short money and then, without fixing the second gear, ran the bike out to 200,000 miles.  He did this several times and did over half a million miles on these no second gear bikes.

I will share a pic of mine.

Venture83.jpg

Ok, that makes the front end start to make a little more sense. The anti-dive units aren't hooked up - the wires are just hanging disconnected - and we're gonna guess that the wiring harness on the bike lacks anywhere to plug them in, then. Any known way to get that functional, or are we going to be flying blind with the schematics to sort out how to get it working? If worse comes to worse we do have the whole original front end from the seller, but we'd rather get the second gen one hooked up and fully operational if possible.

On 8/2/2024 at 4:17 AM, luvmy40 said:

Unfortunately, the frame rot is all internal until it breaks. Odds are it's OK though.

I've brought 2 CLASS modules back to life by re-soldering the pins on the board.

I seem to recall seeing a Hello Kitty themed Venture at one point. Not sure if it was here or elsewhere.

We tried resoldering the wiring harness connector pins like we did for the CMS and no change. Any particular pins we should look at or would it just be best to reflow everything on both boards inside the unit?

Reflowing the solder on the CMS connector got the headlight working correctly at least. Turns out the instrument cluster was missing a couple of the little rubber shock absorbers, too, so those have been replaced as well. The water pump parts arrived yesterday, so this evening after work we're going to try and get the pump rebuilt and reinstalled. And change the oil & filter while we're at it - the stuff in there is very black and looks done for. We've got a 100+ mile group ride coming up this weekend, assuming we get the water pump dealt with we're planning on taking the Venture for a little trip through the mountains :)

Posted

OK.  I like your project bike, even though I'm horrified by the paint scheme you are proposing ( lol ).  Bear with me here for a bit as I'm unfamiliar with the post 86 Ventures.  Your original 83 brake anti-dive system was activated by hydraulic pressure .  Each anti-dive valve was hooked up to the front caliper next to it.   I suspect that the newer model you have is similar.  One side would be electrically hooked to the handlebar brake stop light switch and the other to the foot brake stop light switch.  One commenter suggested that with progressive springs, that entire system is unnecessary.  I agree but short of taking your front end apart I do not know how you would check.  Two other things you should know, if you haven't figured it out yet,:  The front end of the 86 and up bikes used a larger diameter fork tube than the earlier bikes and it is more ridged and stronger than the earlier design.  ( So you should keep it )  In addition, you do not have the original brakes on your front end but the much better calipers from one of the later Yamaha "Ninja" type bikes.  Something like a YZ1000 .  Some person with more knowledge will step in shortly to identify the exact model or you can wander through the hundreds of posts here to find it.  Your calipers look nothing like the calipers on my 86 parts bike.  If you cannot get your air suspension system running, I have a spare one.  Many people here have spare parts they might donate for the cost of postage.  PM me if you want it. There is one more dreary and sad thing I must inform you of.  In the FACTORY MANUAL, for 83 to 85 Ventures ,  the intake and exhaust valve clearances are REVERSED.   This means that the exhaust valves are too tight and the intakes are too loose.  If you intend to keep the bike you must check this.  If you doubt me, check out the used motors on e-bay.  It is frequently noted the compression is low and this is why. 

  • Like 1
Posted

Re-reading your post, I forgot to mention that the original rear shocks were legendary for their reliability.  I'm not saying that its not a good idea to have a spare, but the originals seem to last forever.  It could be that your speedo drive on the front wheel might have a bad ratio for your speedometer.  Perhaps one from an earlier model will fix that.   That's all I got tonight.  Keep us up to speed !

  • Like 1
Posted
15 hours ago, Vickersguy said:

OK.  I like your project bike, even though I'm horrified by the paint scheme you are proposing ( lol ).  Bear with me here for a bit as I'm unfamiliar with the post 86 Ventures.  Your original 83 brake anti-dive system was activated by hydraulic pressure .  Each anti-dive valve was hooked up to the front caliper next to it.   I suspect that the newer model you have is similar.  One side would be electrically hooked to the handlebar brake stop light switch and the other to the foot brake stop light switch.  One commenter suggested that with progressive springs, that entire system is unnecessary.  I agree but short of taking your front end apart I do not know how you would check.  Two other things you should know, if you haven't figured it out yet,:  The front end of the 86 and up bikes used a larger diameter fork tube than the earlier bikes and it is more ridged and stronger than the earlier design.  ( So you should keep it )  In addition, you do not have the original brakes on your front end but the much better calipers from one of the later Yamaha "Ninja" type bikes.  Something like a YZ1000 .  Some person with more knowledge will step in shortly to identify the exact model or you can wander through the hundreds of posts here to find it.  Your calipers look nothing like the calipers on my 86 parts bike.  If you cannot get your air suspension system running, I have a spare one.  Many people here have spare parts they might donate for the cost of postage.  PM me if you want it. There is one more dreary and sad thing I must inform you of.  In the FACTORY MANUAL, for 83 to 85 Ventures ,  the intake and exhaust valve clearances are REVERSED.   This means that the exhaust valves are too tight and the intakes are too loose.  If you intend to keep the bike you must check this.  If you doubt me, check out the used motors on e-bay.  It is frequently noted the compression is low and this is why. 

We're going to try to mess with the air computer module a bit further but it's not looking promising, we'll PM you :) We noticed that the brakes looked off - they're definitely very powerful and stop it quickly.

15 hours ago, Vickersguy said:

Re-reading your post, I forgot to mention that the original rear shocks were legendary for their reliability.  I'm not saying that its not a good idea to have a spare, but the originals seem to last forever.  It could be that your speedo drive on the front wheel might have a bad ratio for your speedometer.  Perhaps one from an earlier model will fix that.   That's all I got tonight.  Keep us up to speed !

Hmmm, hadn't though of that but given everything else that's been modified on the front end there's a good chance that's not the original drive unit. If it's an easy enough swap we'll see if we can hunt an earlier one down.

Got the water pump rebuilt and installed yesterday and rode it up to work this morning. Our commute involves driving through downtown Denver traffic and then climbing 2500' up the mountains at highway speeds so it's a pretty good stress test - we frequently see manufacturer test mules dressed in dazzle camo on our commute route during the summer lol. It's definitely running cooler, though not by a lot. Enough to keep it from bumping against the redline on the temp gauge constantly at least.

  • 2 weeks later...
Posted

We finally got around to ordering a carb synchronizing tool and got the carbs all tuned up and the oil & oil filter changed. She's running really smooth now and accelerates like a bat out of hell. Ran into another weird problem - the temperature gauges starts dropping to zero once we accelerate over 90mph (indicated - so ~75mph actual). Might just be a loose connector or something but it's odd how consistent it is. As soon as we slow down below that threshold it immediately start working correctly again.

We're gonna try and hook up the anti-dive units this week; gonna guess it doesn't have progressive springs based on how severely it's diving on the front brakes. Might try and change the shock oil while we're at it - we did check the steering and wheel bearings while we had it on the center stand but there's no play there. After that we're just going to try and work our way through all the scheduled maintenance stuff so we can get a good baseline to go off of in the future.

Test painted one of the fairing bits that's not currently on the bike! Primer, four coats of gloss candy pink, wet sanding down to 1000 grit, and three layers of matte clear coat makes for a very lovely satin pink finish 😁

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There's several spots on the fairing where mounting tabs are snapped off and long gone. The plan for anything we can't repair is to drill holes and use contrasting cyan zip-ties for a kinda drift-stitched, kintsugi look.

  • Like 1
Posted

Before you drill holes and zip tie stuff together,  remember all the cool stuff you can do with epoxy and fiberglass.   West System Epoxy has some excellent tutorials online and most of the broken tabs can be recreated with fiberglass.  You can look at my bike, no visible damage to the plastic yet there are very few places that have not been repaired.  I even reproduced the mushroom shaped pins that push through the rubber grommets to hold on the side panels.  Fiberglass is tough stuff.  Its stronger than the plastic you are repairing.  The broken tab on that lower fairing section connecting the right and left sides is a perfect example.  You can recreate that tab using the other side as a model.  You can drill it, file it, sand it, paint it.  What's not to like ?

  • Like 1
Posted
15 hours ago, Vickersguy said:

Before you drill holes and zip tie stuff together,  remember all the cool stuff you can do with epoxy and fiberglass.   West System Epoxy has some excellent tutorials online and most of the broken tabs can be recreated with fiberglass.  You can look at my bike, no visible damage to the plastic yet there are very few places that have not been repaired.  I even reproduced the mushroom shaped pins that push through the rubber grommets to hold on the side panels.  Fiberglass is tough stuff.  Its stronger than the plastic you are repairing.  The broken tab on that lower fairing section connecting the right and left sides is a perfect example.  You can recreate that tab using the other side as a model.  You can drill it, file it, sand it, paint it.  What's not to like ?

We've been epoxying stuff together that wouldn't zip tie well - that lower fairing was in three pieces - and we're pretty familiar with fiberglassing - we built a boat a few years ago and learned how to do it for that project. Mostly this is just an artistic / philosophical decision; we want it to show its scars rather than erase the history, if that makes sense? That's why we're using pretty, colorful zip ties for the repairs.

Some of the mounting brackets and pins and stuff we will be recreating since zip ties won't necessarily work right in those locations. They're mostly going to be for the random cracks here and there.

  • Like 1
Posted
21 hours ago, HeatherFeather said:

We've been epoxying stuff together that wouldn't zip tie well - that lower fairing was in three pieces - and we're pretty familiar with fiberglassing - we built a boat a few years ago and learned how to do it for that project. Mostly this is just an artistic / philosophical decision; we want it to show its scars rather than erase the history, if that makes sense? That's why we're using pretty, colorful zip ties for the repairs.

Some of the mounting brackets and pins and stuff we will be recreating since zip ties won't necessarily work right in those locations. They're mostly going to be for the random cracks here and there.

Interesting concept. It's almost like the beginnings of the rat rod mantra / clearcoat it.  

  • Like 1
Posted (edited)

More painting done!

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Allowing for curing times and when we have time to work on it, we ought to be finished about a week from Friday :)

Edited by HeatherFeather
  • Like 3

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