il Crustico - '73 Moto Guzzi Eldorado Basket case Restoration

How do you like the f650? I’ve been looking at maybe getting a f650gs Dakar when I get out of school. The Dakar model is quite different I think than yours, but the base bike is similar I think. Seems like a decent option for a not too crazy heavy adv?


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Its a great bike. The GS is a twin, and the ST is a single, so I can't speak for the engine, but mine has been reliable and its a nice comfortable ride.
 
The 2000-2007 F650GS/Dakar is a single. My brother has a 2002 F650GS. its a decent entry level bike. It handles great. My only gripe about it is the fuel injection mapping is not great. Its a common issue on the early models with poor combustion chamber design and running lean to get by emissions. After 2004 BMW switched to dual plug and changed the mapping and I think they are supposed to be better.
 
The 2000-2007 F650GS/Dakar is a single. My brother has a 2002 F650GS. its a decent entry level bike. It handles great. My only gripe about it is the fuel injection mapping is not great. Its a common issue on the early models with poor combustion chamber design and running lean to get by emissions. After 2004 BMW switched to dual plug and changed the mapping and I think they are supposed to be better.

The single is the one I’d be interested in. Supposedly very reliable. I just can’t get on board with the 500+ lb “adv” bikes. Totally cool for road touring, but no way I’d take one off road beyond a well kept gravel road. That’s the appeal of the 650 to me, 420 wet (supposedly) I’d feel ok at least going down some rougher stuff


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A lot of traveling lately but I’ve been able to plug along on the Guzzi a bit here and there. We were able to save the original left side head with the bad threads, the other available replacements both needed more extensive work so the Guzzi Docs machinist was able to weld some aluminum and re-tap the threads.

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In a couple weeks I need to switch out the coarse media in the blast cabinet for the glass beads again to match this head and the transmission case.

I reassembled the front forks, installed new steering stem bearings and got the civilian bars fitted up. Never assembled a front end quite like this, the tool threads into the fork stanchion and you draw it upward into the top triple tree, tighten the lower pinch bolt, and then put the big plug in and draw the stanchion all the way up.

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You are making a lot of progress. Some of the Brit bikes use that type tool to pull up the fork leg through the shrouds.
 
Can't believe the fast progress on this project, looking great!
 
Thanks all, I just passed the one year mark so it’s time to kick it into overdrive.

We pulled the bearings out of the trans cases so I could bead blast them to match the crankcase. Gave em a once over, clean clean clean, and a coat of shark hide and dropped them off at the Guzzi Doc’s for reassembly. We’re shooting to have the bottom end and trans buttoned up within the next month or so, and my goal is to have a roller before then so I can move the bike out into the garage and onto the lift.

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I picked up some more parts from chrome, and dropped off some more parts. I had the fender braces and brake lever “chrome” powdered but now that I’ve got a bunch of rechromed bits those look like shit.

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I blasted and powdered the headlight bucket gloss black. I need to fill in some pits so once I get around to that it’ll get painted.

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Also placed a big order from a fellow in Italy who has a small fabricator reproducing some of the chrome accessories. Front crash guards, rear crash guards, cylinder head guards, grab handles and a luggage rack.

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Before the holidays I finished up bead blasting the rest of the engine bits including the new 88mm cylinders, valve covers, timing chest cover and oil pan.

I brought everything up to the Guzzi Docs shop where he had the bottom end and transmission back together. We replaced the cam due to some rust/pitting, most likely just from sitting for so long, and had to verify the cam timing.

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From there I assembled the heads and rockers, torqued em down, and loaded it all up and headed home.

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The engine and trans are chillin in the basement for a bit until I’m ready to install.

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Your work is coming up beautifully as always man. So excited to see this happening.
 
A few months ago I picked up a pair of used Progressive shocks on eBay for a deal. When they came in, the bushings were missing and I was not able to find a suitable replacement off the shelf.

Having run into the same problem before, I went ahead and took some measurements and 3d modeled a mold to pour some urethane rubber into.

I ran through a few prototypes until I found a design that would work. These are single use molds which is fine for a limited run like this. I used some ease release to treat the mold and mixed up some 85a urethane rubber from Smooth on. I added some black UV dye since it comes off white.

Once poured I cut the sides of the molds to get the bushings out, then trimmed the flashing with an exacto knife.

I had ordered some bushings from Amazon that were too small but the metal sleeves fit the mounts for the frame. I was able to keep those for free and just needed to trim them down a bit to fit this application.

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And here are the finished bushings installed. Just need to polish up the shocks and we’re good to go.
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That's really nice skills. Is that 85a urethane going to hold up for that kind of use? (Not being critical, just trying to educate myself.)
 
It should, from what research I did most bushings for car/motorcycle suspension are between 70-90a hardness. The one bushing that came with the shock was definitely way softer than these so I'm pretty confident, but only putting some real miles on the bike will tell.
 
Last week I took the previously-blasted-then-re-rusted fenders down from the loft and used the nice weather to get them blasted. They don’t fit in the cabinet so outside with some good PPE does the trick.

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I blast, etch to kill any remaining rust, and in this case I’m applying filler directly to metal because of the sheer amount of pitting. Got them close enough to shoot with epoxy primer and I will do any touch up and missed spots once the primer is fully cured.

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For the headlight bucket, I blasted to bare metal, powder coated in gloss black to have a durable finish on the inside, sanded and filled the pits on the outside and shot with epoxy primer.

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I also had a dumbass moment as i was prepping to coat the front hub, set it up on edge and it fell off the work bench onto the concrete. I’ve got a line on a good used one and hopefully score some new hoops as well.

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