Still working on the front end, measured for spacers and seeing if my master cylinder is still good (draining it right now). One thing I didn't think of when going with the R1 front end is how to mount the headlight. It's not like I can just buy some headlight ears. I seriously doubt anyone makes them in 500mm. Ha! A bracket will have to be made and I'm thinking about the ignition lock mounting points on the GSXR top clamp as the new mounting point? Looked at an old Suzuki tank to swap in, but the tunnel was too narrow. The XV backbone is substantial, to say the least. Thought about buying an RD 250 tank off fleabay, but it was heavily rusted inside and had big dents. Seller still asking almost $100 for it plus shipping and I don't know if it would fit. Too big a gamble. Beat up and rusty XS ('76) tanks are going for $150 or higher, as well. WTF? Guess I'll have to settle for the stock XV tank for now... I just am not crazy about the shape.
Finally got all the old gasket material off the case covers. Man, was that a tedious job! Covers painted with Rustoleum high heat primer and high heat gloss black. I decided to use the hub cover that came with the rear wheel to front conversion. I was just going to leave it open. Anyway, I started drilling out the cover and will screw it to the hub with either small polished Allen head screws, or black Allen head screws.
Fitted the cleaned and rebuilt carbs. Engine looks amazing and I didn't polish a thing on it!