Lady Amalthea

[JPSmee]

The name has finally been chosen. My wife came up with it, and her explanation of the background of the name was perfect for the project - Lady Amalthea

The name comes from one of her favorite childhood books, The Last Unicorn

In a nutshell, the protagonist is turned into a human and learns to experience everything for the first time, as if given a new life. How fitting for this project

Okay, now that the background of the name is covered, it's time for pics and plans:

The bike as it was when I got it (some of you have already seen this from my earlier posts):


The inspiration for this project actually comes from the bike that I wanted when I got the "bug", the Harley Sportster Iron 883:


I fell in love with the super blacked out look that seemed to defy the normal chrome-centric look for cruisers that I'm used to.

Initially, I wanted to go all black for my ride, but shinyribs' amazing engine cleanup (below) really got me re-thinking if I should black out the engine, or make it shiny:


Still not sure on that part.

As for the pipes, I actually really like the 2 into 1s that were on the bike when I got her. They sound great, and have a really fun look to them. Unfortunately, they are badly rusted and chromed.

Look at the two middle header pipes to see what I mean about the rust:


This is where I started my first real work on the bike (mind you, the most complex mechanical thing I've ever done to a vehicle is change a battery up until this point):



Had little trouble getting the exhaust off, much to my surprise

The next step is to grind off the rust, and apply some paint. I'll update with pics once I get a chance

[Daddyman]

JP great name for the bike!  The Blacked out look is cool, I was thinking about your pipes and thought you could save some work if you wrapped the pipes like in this pic.  I think it looks kinda cool

[shinyribs]

Lady Amalthea...has a rather regal sound to itI like it!Thank you for the kind words about my engine.I would like to note:the clear coat paint i used has yellowed quite badIm not happy about that,i dont want anyone else to have the same problem.

      I agree with Daddy-0 on the header wrap.I have a roll of black wrap waiting to go on!
See how dirty the jugs look?Thats not dirt

[JPSmee]

It is delightfully regal, I agree

I actually already started painting the headers+exhaust last night (partially because I could only get one of the headers separated, but also since I'll be having them be the same flat black as the exhaust I figured it wouldn't hurt) . . . so it's already a little too late for the tape (I must admit, I think they already look better painted). I also got all the rust and grime off of the header collars, and painted them with aluminum engine paint.

With the now shiny collars, I'm thinking I'll go ahead and black out the engine. The contrast they have against the pipes is really really cool looking, and I think they will stand out even more against a black motor.

I saw shiny's post on how he removed his engine from the frame, and might be doing something similar . . . does anyone have any good write-ups or links for getting the tank off cleanly? I don't want to get any leftover gas all over the place, if I could avoid it.  I'd like to get the badges chromed up and go flat black on the tank/side cover (again, going for contrast while keeping with a mostly blacked out look).


I wish I took pics last night when I was done with the pipes, but I was tired and didn't want to get paint on my phone

I'll post pics when I get home tonight.

[shinyribs]

Going black on the engine is something i wish i had done,to be honest.It would be much easier to touch up in the future,and keep it looking fresh.I have never been one for foresight.

[JPSmee]

Do you know off-hand if I need to add anything after the engine paint, or is it safe to just paint and go?

[JPSmee]

Here are the header collars post-grinding+paint:


And exhaust:


When I attempted to put everything back on the bike, I found it next to impossible. I put the spacers at the end of the headers (small end facing engine) and under the collar as they were when I took it all off . . . but I can't seem to get the collar to tighten up flush against the engine .

I don't want to over-torque things, but I just can't seem to get these things on at all. Any suggestions?

[TOOLS1]

They do not go flush with the head! Just snug them up even.
TOOLS

[JPSmee]

That is a HUGE relief.

Going to do that now before I go to bed (want to ride to work since the forecast decided to clear up at the last minute )

[JPSmee]

Got the tank off and got the new choke cable installed (thanks everyone for the help!). Here she is in a more bare form:


With the tank now off, I've begun removing it's original paint (wishing I had one of those soda blasters I've seen folks posting about right now . . . sanding gets old fast ):


I also started prepping the tank badges for the new look they will have:


Tonight I plan on priming the tank and chroming up the badges. If my new crashbar (thanks shiny!!!) today as UPS indicates, I'll be prepping that too for the black in it's future

[Piute]

   No close,thats no way to treat A Lady(Amalthea).
 So getter going getting cold out ,looking like some work being done though keep her going there JPS
    crash bar seems I should get mine on and maybe painted
                Piute

[shinyribs]

Lol piute,no clothes.I love to see a bike stripped down and then watch it go back together piece by piece.Its a lovely thing

[cityslicker]

Looks great so far.

[cityslicker]

Looks great so far.

[Lucky 1]

Don't grind off the rust.
Maybe a sanding disk(flap wheel) at the most.

Use a wire brush instead, then treat with phosphoric acid. It turns the iron oxide (rust) into iron phospate
and stops the corrosion process.

Then degrease, rinse with water and paint within 4 hours.

Before you paint the tank.
Put a thin layer of Bondo all over the tank. NOT just in the low spots, then sand and paint.
A body shop guy taught me that.

[LukeM]

Correct me if I'm wrong, but aren't there compressible washers inbetween the head and the exhaust pipe? Copper, sometimes aluminum. I know my Shadow has them, cuz I put them in when I rebuilt the exhaust.

If they are there already, never mind. There should be little L shaped pieces on either side of the exhaust pipe inlet, which the collars press on to seal the pipe onto the head.  Snug is good: you can test for leaks with some chalk line dust or feeling for air leaks (watching out for the skin-searing temp on the pipes, of course).

Looking good...just go slow, and take your time.  The devil (and the attention) is in the details.

Luke M

[JPSmee]

Update:

Freshly chromed tank badges:


Speaking of the tank, here it is drying from it's second coat of lovely matte black:


The Lady has a new accessory (thanks Cabreco for making me aware of these!):


Tomorrow I'll be putting things back together. The engine will have to wait for colder weather . . . it's still too nice to stop riding!

[JPSmee]

LukeM, yes there are. They do prevent the collars from fitting flush with the engine, which is what was confounding me when I was messing with that.

[shinyribs]

Cool! I have been considering a windshield myself,but the wind kinda helps to balance me out when leaning on the clubmans.I spy a very ugly home made box in the background

Ditto on the too nice to stop riding.I ride in 33 degrees the other night and it was not bad at all.As long as the roads stay dry,i believe i will be able to ride year round

[JPSmee]

. . . I was meaning to comment on that box. It proved . . . difficult to open

Thanks again sir. I can't wait to get the bar painted and on the bike, just need to pick up some bolts for the bottom brackets and I'll be set .