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Have been through some really turbulant water these last few months which has held up the Interpol project.
Got the motor and gearbox sent out to a british shop which still deals in repairing the Interplods.
Also got some bits powder coated - bummer; The frame serves both as a pleunum chamber and oil tank, why the internals need to be squicky clean. When I got it back from PC it had loads of sand lodged inside both oil tank and pleunum much of which had become mixed with PC.. Back to be redone it goes luckily the bloak who handled it is a great guy.
Hopefully soon I have something substantial to report!
Here we go.
Reworked the tank plug, layered it with masking tape (regular stuff this time, the blue was damn expensive!) and layed down six layers of cloth on the buttom and tunnel. Managed to lay each layer down as single pieces and it did work surprisingly well. One tip, cut your pieces so that they are AT LEAST 50mm to big around the egdes, it did get tight a few times.
Trimmed the edges down, kamfered a 1½ cm edge all the way around the foam plug and filled it with a mix of chooped fibres and epoxy.
This sandend smooth today and covered with masking tape and wax and got on to lay six layers on the top today, this had to be done in three sections as the cloth wouldn't drape all the way over.
The scribbles on the side where markings '90' '45' etc to keep track of which drape was which.
Got into splitting the mold, had to bring out the big guns for this one. Maybe six layers was a little bold but plenty of violence later the top and buttom finally parted ways.
Luckily not too many bubbles and those that were were superficial so just attacked them with a dremel and wiped the parts down with acetone.
Back on an international level, we danes need to keep together.
Got onto detailing the already made parts and making a front fender and side covers. Was in doubt wether or not the buttom of the tank would clear the vacuum housings on the carburettors so lengthend the cut just to be on the safe side. The top got the worst of the lumps and bumps sanded down and cleaned off with acetone.
The side covers I've been working on the last couple of days, they have the same six layers of cloth as they are likely gonna the thrown around a lot.
The front fender was molded over the stock steel unit. Laid on six layers but when the fender came off it did prove a bit flimsy sideways so roughed up the inside with 60 grit, cleaned it off with acetone and laid in four 45 degree layers for sideways rigidity.
EDIT
While waiting for the engine to return I went on to assembling what I could - Changing the fork tubes and springs getting the front end back together, assembling the back end and getting tires mounted and balanced so if the front and read ends just seem to spring out of thin air that's why.
So this is where the old girl is at some tedious 10 months down the line. Didn't get the engine back until the friday before last and didn't have time to begin work until today. From here on out; Straight priorities got less than a month before I am literally thrown out of my workspace yikes!
X Mounted centerstand to engine
X Test mounted rear swingarm and wheel
X Test mounted frame, suspension and front fork
X Frame cleaned internally and mounted
X Front fork, brakes and wheel mounted
X Clipons, levers and controls mounted
X Rear swing arm, frame plates, brakes and wheel mounted and tightened down
X Side covers, tank and front fender roughly mounted and mounts drawn up
X Mounts for tail and seat drawn up
X Misc parts mounted and adjustments made
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