Thought I'd start a build thread it bought a mk3 back in October to use for a bit of laning and a commute a couple of times a week.

I soon found that the previous owner had fiddled a lot and didn't know what he was doing.
Then when my engine begine sounding more like a diesel I decided it was best to go for a rebuild.
But while I was at it I thought I would rebuild the entire bike aswell.

So here it is before the strip down



When I began taking the engine apart I found my piston to have a wear mark



I stripped the complete engine and have split the cases etc this will all be rebuilt over time.

The frame etc will be powder coated.

PmH first parts are back from the powdercoaters today and here they are

Candy red hubs and yokes





These will be going on a satin black frame

Need some stainless spokes now to lace the hubs upto the gloss black rims.
If anyone knows the best place to get stainless spokes all. Help will be appreciated

Piston just looks old and rings are obviously worn out - loads of 'blow by'.

Finally got round to emptying the cases of bearings



So I'm thinking of having the case powder coated before I put new bearings in is this recommended?
And is there any drawbacks?

Got my frame back from the powder coaters. Been done in satin black







The crank cases have been glass bead blasted. I'm a little unsure weather to just leave them bear metalwork or if there's something I can do to make sure they stay looking relatively clean

Looking good. Probably whether the bike is for show, or go will dictate how much work you put into trying to keep a concourse condition.
Mike

It will definatly be used as intended offroad but also hoping to put some supermoto wheels on for the road. I was ju8st wondering if i should coat it or anything to keep the cases in a reasonably clean condition

Got my wheels put together today. Just need bearings balancing and tyres putting on now

Tomzed,

Please keep a record of how much everything is costing you, " I am always interested in final costs of a refurb".

Include everything, tyres, valves, rim tapes, price to balance wheels, all powdercoating, every little item adds up. Once you start its like a disease, everything needs painting, plating, coating or replacing.

My guess is that you will not be far off £1,000 on a small refurb.......£2,000 on a full one.

i will do i expect it will be nearer the second value. all depends on the final finish as im not decided yet on what to do with suspension etc. rebuild to standard or change forks for some off somthing else? or try and have them uprated.

i also want a set of supermoto wheels.

Powder coat the cases. Much, much, better - cleans with a wipe and won't corrode as the bare ali will do.

I was going to powdercoating the case but was a little worried it would all chip whilst driving bearings in.

Dropped my suspension off at shocktech today to see what they can do with it.
One of my fork bodies is badly corroded and flaking.
So I was talking to them about using cr forks and if the bottoms arnt the same trying to change them and put the crm ones on.
Does anybody know what year cr forks fit into the crm?

No need to worry about the engine finish.

Just make sure you use ACF 50 on a regular basis on aluminium, amazing stuff and have been using it for many many years in aviation.