the Hunley

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  • the Hunley

    Back in 2013 I bought a GL1000 to "restore". The frame is a '78, but I discovered that it has the '75 engine, so restorations went out the window. I am building a custom cafe-style out of it (as if there weren't enough of those around already). I dove right in and after pulling the belt covers off discovered that the engine had been partially submerged for quite some time. Sadly, one sides exhaust valves were open, and water entered the 1 & 3 cylinders. I spent weeks setting on the floor with single-edge razor blades clamped in forceps scraping the rust from the cylinder walls. The head and block on that side were not true, either. I filed and finished with glass plate and silicon carbide paper. Blued nice, then. Compression test was still bad and I discovered the valves were all leaking. I let the engine set for a while and took the frame to bare metal, primed, and painted it. Rebuilt the carb rack. Found a fiberglass seat pan and built up foam for a cafe seat shape. Then work kept me busy until last September, when I was laid off on the day that I had planned to retire. I have since pulled both heads, had the valve seats ground and installed new valves and seals. Compression test looks good, now. I have cleaned and painted the engine cases and polished all bare aluminum. The Comstars have been cleaned, abraded, primed with etching primer, and painted with black wheel paint. I plan to paint them again with bronze wheel paint once new tires are mounted. The seat pan was taken to an upholstery shop today to have the seat covered. I still have not started the engine. That should happen some time this summer.
    The name for the bike borrows from the H.L. Hunley submarine that was the first successful military sub. she was lost after her first mission during the war of Northern aggression, and found in the '90s, raised around 2002 and rests in a research center at the old Navy base in Charleston, S.C. She is not named after the ship, but rather in honor and memory of the inventive designer of the ship and her gallant crews (of which she lost three).
    "Love 'em all.... Let God sort 'em out."

  • #2
    More pictures please!

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    • #3
      Originally posted by jmohme View Post
      More pictures please!
      Frame as of several years ago (painted). There is not really a lot of progress that shows in pictures yet. Maybe in a couple weeks when the engine gets the frame back on it.
      "Love 'em all.... Let God sort 'em out."

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      • #4
        Oh, and this is what it looks like inside the belt guards now. Before the cases were cleaned and painted. I do a little (sometimes very little) on it each day. Today I just cleaned some bolts. Too cold/humid for any painting (which it needs a lot of).
        "Love 'em all.... Let God sort 'em out."

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        • #5
          Head and block work.
          "Love 'em all.... Let God sort 'em out."

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          • #6
            Results. This is right bank (1 & 3).
            "Love 'em all.... Let God sort 'em out."

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            • #7
              Still, the compression was lousy. I ended up buying all new valves for it and having the seats ground. The seat grinding took all of ten minutes and cost ten dollars! Compression is now 180,160,160,160 (was 75,129,129,136 when first checked, 155,135,100,150 after cylinder scraping and head leveling) I expect it all to improve and level out once I get it running.
              "Love 'em all.... Let God sort 'em out."

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              • #8
                I think that all of the parts needing painting other than those that will get dark green (side panels, shelter sides, fenders) have finally been de-rusted, cleaned, primed (etching primer) and painted (most clear coated also). The front fender has been sanded and primed. The side covers have been sanded, primed, sanded, sanding primed, sanded, primed and ready for color. Only the rear fender and shelter sides need preped for color. The saddle is at the upholsterer getting the vinyl sewn. I cut the rear fender down today and just need to pound some bumps in it for mounting before sanding down the chrome and then priming it.

                But the big news for today is..... The frame is now back on the engine!!!!! Quite a milestone for me. The wife helped jockey the frame with me and I took her out to lunch to thank her (we rode the GL1800 and rode over Norris Dam on the way home).
                "Love 'em all.... Let God sort 'em out."

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                • #9
                  Lookin' good!

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                  • #10
                    Pressed the water system up with ~5 psi air to look for leaks. Soap solution didn't find any (although it won't hold pressure). Will listen with stethoscope tomorrow when the wife isn't using the washer and dryer in the garage.

                    Oh, and found three more parts to clean, derust, and paint (upper and lower radiator brackets and radiator screen). Not counting the calipers, but I don't know yet what I'll need to do to them. I'll burn that bridge when I get to it.
                    "Love 'em all.... Let God sort 'em out."

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                    • #11
                      After trial-and-error with the stethoscope, decided primary leak was on the radiator itself (small one due to an ancient o-ring on the thermostat housing). Pulled it back off and took the cardboard that I had taped over the coils off. Pressed up and it was obviously from a small hole on the edge of a tube. Luckily, it was at just the right spot to be able to easily solder. Back on and holding pressure well.
                      "Love 'em all.... Let God sort 'em out."

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                      • #12
                        "Love 'em all.... Let God sort 'em out."

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                        • #13
                          More progress. Radiator re-mounted with new hoses, grill added. Swingarm mounted. beginning to put the wiring harness back on. What joy!
                          "Love 'em all.... Let God sort 'em out."

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                          • #14
                            Carbs mounted up today. Pretty easy with the shelter still off and wiring not that far forward. No photos, though. Thinking triple tree and bars next to let me run the throttle, choke, and clutch cables while the shelter is still off.
                            "Love 'em all.... Let God sort 'em out."

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                            • #15
                              Looking more closely at the triple tree. Not only needs paint - it needs new bearings. All Balls on order, now to figure out getting the old off and new on. Might do a little lathe tune-up first, I think I'll be needing it.
                              "Love 'em all.... Let God sort 'em out."

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                              Flat Four-um

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