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Havent forgotten about this thread. Ive been waiting for the tank to get real nice and dry before wetsanding and polishing. I did that this past weekend. Still might need a little more polishing, but it looks pretty damn good. Then I need to mount the emblems back on the tank and Ill post...

So I got the bike fired up pretty easily. At first it was running pretty rough and couldnt really rev much past 5-6K without stumbling. It idled pretty well though. I started out with the original jet sizes for the CL200. I knew that this wouldnt work long term since I changed both the...

Yep. Bolted through the frame. You got me thinking though that over time the vibration might damage something. Maybe I need to add another thick rubber washer so I have them on both sides of the bracket. A rubber sandwich instead of just a heat insulation point like I have now. That would...

Forgot to mention, you can see how I hid the exhaust-to-frame bracket in the 4th and 5th pics above...the mount is insulated off of the frame with a rubber spacer

Bunch of new seals on both sides of the engine, new rear brake switch, kick starter seal, etc. Had to replace the left side points base as mine was cracked on the bottom for some reason. The bearing surface was still very nice on the one I pulled off. Surprisingly the bearing surface was also...

Here are just a few detail shots to show how I ran cables and wiring. I tried forever to get someone local to me to CO2 blast the engine but could never get anyone to commit. So I bought some Aluminum Brightener from Napa and gave that a shot. It kind of worked. It etched into the aluminum...

Tires: https://www.amazon.com/gp/product/B003CKB9TG/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1 https://www.amazon.com/gp/product/B003CK7LPW/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1 They fit perfect for me. No rubbing anywhere.

Surprisingly havent injured myself too bad on this build. Couple razor blade cuts as usual. Worst one was when I was using the angle grinder with a cutoff wheel to cut something off. Dont remember what it was. It took awhile to cut through and the piece I was cutting off ended up dangling...

Figured I would type out my costs so far: carb manifolds - 50 rear shocks - 61 brake light - 25 headlight brackets - 31 turn signals f/r - 60 ignition switch - 9 reg/rec - 38 ignition coil - 20 engine gasket set - 30 exhaust guard - 50 carb rebuild kits - 42 wheel bearings - 35 ss engine bolt...

Here is how I ended up mounting and hiding the SparcMoto reg/rec...

Here are the baffles I ended up using for my exhaust. They fit perfect and are good quality: http://www.nichecycle.com/ncs/categories/exhaust/baffles/009-0217-exhaust-by-mac-performance.html I drilled a hole on the inside end of my tubing and welded on a nut so I could use a bolt to take them...

Here is a pic showing the clearance I had to open up with the rear sprocket for the shock to mount safely. Worked out very well in the end but it certainly took a few days to get it all figured out.

Thanks for the tip. I use that stuff at work sometimes. Fortunately at this point I have the wiring completely working. I removed the horn because I didnt like its stock location. I will probably install a hidden one at some point. I also did the modification to the wiring in the headlight...

I forgot to add above that you can see the start of me trying to figure out a velocity stack solution. Ended up using those exhaust couplers I got at the flaps. They fit almost perfectly. No frame modifications either.

At this point it was about time to toss the dirty engine back in there and figure out what I was going to do with the exhaust. After a bunch of research and thinking things out I decided to go with straight pipes all the way to the back. Bought some tubing online and started welding them up...

After I was satisfied with the rear setup, I moved to the front. I didnt like the bike being supported by that one old shock tube any more than you do. I ended up buying 2 front shock tubes off of ebay because both of mine were slightly bent. Full rebuild of both tubes and got the lowers...

All new wheel bearings, swingarm bearings, and steering bearings. Started to fit the frame all back together. I wanted to get the bike off of the ATV jack and onto the centerstand. It wasnt very secure on the ATV jack and I was getting worried it was going to tip over. Probably took the rear...

Bought a new set of lower gloss black handlebars and got everything mounted up front. Had to drill all of my own holes to run the wiring. That was a pain in the ass. Gauges all cleaned up.

First thing I did was to cleanup the wiring harness and reinstall it. It wasnt as bad as I thought it was going to be. Had to make some modifications for a few things. Also had to rearrange everything that goes under the seat to fit with my new battery situation. Here is what I ended up with.

Got all of my parts back from the powdercoater and they look great. You can see I left the inner rear fender in place. I did trim it up before I sent it to get coated so it was symmetrical. While I do like the look of an uncluttered triangle, I dont really think it is practical for keeping...