Hoosier "Cobra" project begins; yes...another T500!!

[CobraRad]

As some already know, I picked up this ’69 T500 this past fall. I’ve been holding off on a “build” thread, simply because I haven’t really “built” anything yet!
The bike was semi-local in northern Indiana, and the PO delivered it to me, with a box full of parts. Not a true “basket case” as the bike was complete enough to run; but wouldn’t now due to lack of a battery and dirty carbs. The seller seemed like a good guy (after all, he delivered it 60miles!), had no need to lie, and left me with his contact info, in case I had any questions. So I took the chance, bought it and started sorting it out. BTW, it came with a clean Indiana title, so that was the first step in the right direction.
The box o’ parts contained the original airbox and air cleaner, 2 additional carbs, the gauges and guage bracket, front dampener, some gaskets, a bunch of misc bolts, and a few extra pieces like sprockets, etc. I took a quick inventory and decided that most of it was junk (except for the gauges, of course!).
Here are a few pics of the bike when I rolled it into my shop…

 

[CobraRad]

She had a beautiful flat black over blue over read paint job. After a quick survey, I decided the only way to know what I had was to start taking it apart. That’s when I found a few issues… 1. Cracked engine case… not a critical part of the case, but still cracked and bent. It looks like someone got carried away trying to loosen a bolt and twisted a bit too hard.
2. There was also matching damage on the sprocket cover… needs to be replaced.

3. A wiring disaster… the gauges and turn signals have been removed, so the wires are just dangling. I found a bunch of wires tucked into the headlight bucket…not sure where they go yet.

4. Missing front fender.
5. Leaking and badly painted rear shocks. just going to replace these…
6. Broken clutch cable.
7. Missing tach/speedo cables.

 

[CobraRad]

However, the good news… frame and engine serial numbers match, all the chrome was decent, hardly any rust, and the aluminum parts were mostly salvageable.

Here are a few pics of disassembly…

 

[CobraRad]

Once I got it stripped to the frame, I made the decision not to cut off tabs, etc. so that if so desired, it could be restored/returned to a stock t500 at some point in the future. I brought the frame and swingarm to a local powdercoat company who stripped and blasted them, primed/sealed them/ and powercoated them charcoal grey.

before:

after:

 

[CobraRad]

I spent some time sanding the metal parts and prepping for paint; but haven’t decided on a color.

I did a quick cleanup on the wheels, and I think they will polish up real well. The brakes/ brake pads are good, just needed a good cleaning…

 

[CobraRad]

While cleaning up the stock exhaust, I decided that I might go for something a little different. So I went shopping across the pond!! Paul from Titan Performance came through, and…

While I was at it, I decided that I really liked their rearsets, so I picked up those as well! Careful, you might need sunglassed for these 8)

 

[CobraRad]

Why not go the rest of the way… and build a “Titan(Performance) Cobra”! So I added a seat to the order, and then had to convince my wife that I was not dealing in ancient Egyptian antiquities, nor did I spend time looting Cairo during the recent riots!

One little problem though… their seat is fantastic and very well built, but is a bit short when using the stock tank… details, details...

 

[CobraRad]

This week I intend to break down the engine for a visual/mechanical inspection. It showed good compression when I tested it, but figured I would replace gaskets and seals and whatever else it might need.

Also, por-15 on its way for tank treatment. There is some rust in the tank, just being better safe than sorry...

 

[Basement rat]

I dig the black and silver myself.

 

[Reinhard]

Looking good. While you're at it just go ahead and spend the 400 for a tank. Tell your wife I said it's okay.

 

[Basement rat]

Better yet, dont tell the wife.

 

[Wingspan]

Wow, you've been making great progress! Is there a dent in one of the your new expansion chambers?

What are your plans for the tank?

 

[johnu]

Nice project you have going there. I think the dent Wingspan can see on the expansion chamber would probably be hidden. It's been a bit quiet on the T500 projects just lately so good to see yours moving along quickly, mine has almost ground to a halt.

 

[Cafe-XV750]

I like it - watching!

 

[CobraRad]

Thanks all...

There is a small dent in the expansion chamber, but as Johnu pointed out, it will be hidden when they are installed. Otherwise, they are flawless and most definitely a work of art! No pics right now, but was able to break down the engine/trans today (thanks for the advice wingspan). Looks better on the inside than I thought it would. Someone has been in there before, the gearbox oil modification has already been done! I stripped out a couple of screws, so I will have to repair those. Then I'll move on to painting and reassembly. I will post pics later tonight or tomorrow. Until then... Cheers!!

 

[29 palms]

Why not go the rest of the way… and build a “Titan(Performance) Cobra”! So I added a seat to the order, and then had to convince my wife that I was not dealing in ancient Egyptian antiquities, nor did I spend time looting Cairo during the recent riots!

haha that has the perfect shape, too funny.

 

[Juggernaut]

I see your from Valpo. I'm just north in La Porte. My bike is in 100 pieces but she will be whole again sometime. Where did you get your powder done and could you tell me the price? If you need help with anything let me know. I don't have a ton of motorcycle experience but I know a lot of people who do.

 

[CobraRad]

Juggernaut... sent you a pm with the powdercoat info.

 

[Titan performance]

Hi Tim....glad to see you started your build thread. there can never be too many T500 projects to look at !
I must say, your 69 looks exceptionally clean and straight.....the sort of bike we dream of finding tucked away somewhere. We have never owned a real early bike like yours with the different style tank, but by the looks of it, the tank is the same shape where it meets the seat, as the later T tank.........and as I said on email, I have just started another of my bikes, and like you, I'm having the race seat and stock tank, so we shall be extending a seat to meet the tank, along with full upholstery to go with it.

It seems things have gone just a little quiet on the 500 builds, so it's good to see you start a new one !
We shall of course be watching with great interest, and chipping in now and then.

Best regards, and good luck with the project....

Paul and Tim Titan Performance.

 

[zooke581]

Looking good. Has come a long way since you picked it up. Looking forward to watching this build.