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Buell Forum » Old School Buell » Archive through January 16, 2012 » Kooks header dent removal « Previous Next »

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Jcs64
Posted on Saturday, December 10, 2011 - 09:15 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I just picked this '00 X1 up a couple weeks ago and it wasnt supposed to be a project, but just like anything I buy, I couldnt leave it alone.
Ive already used up one buffing wheel while working over all the aluminum bits! The Kooks header was on my todo list "at some point", but I couldnt stand looking at it all banged up anymore.

So out came the hacksaw!
(Id hate know how much this system cost new. Theyre were also traces of ceramic coating under the crappy black paint!)

After cutting off the dented pc, I put a pc of 1" bar stock in the vise and slipped the header pc over it.
It took me a while working it w/ a body hammer but It didnt come out too bad. I would have liked to keep going to remove all the nicks but I wasnt sure how much material was lost on the rd.
The thought of polishing was thrown out when I I tried to sand it w/ 120 gritt! Must be the heat cycles messed w/ the makeup of the 304 stainless. This metal was HARD and it took hrs to even get this finish w/ the 120 gritt. (very odd)

Not perfect, but nolonger such an eyesore.
4000 grit paper and WD-40 did a nice job on the aluminum tail also.

Next on the list is a paint job (gloss black /brushed alum 3D BUELL decals) and carbon fiber gas tank trim pcs (looking to buy if anyones selling).

Later, Jeff
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Onebadx1
Posted on Saturday, December 10, 2011 - 09:47 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Very nice Jeff.

"but just like anything I buy, I couldnt leave it alone"

I think that's the problem with most of us!

Get a cover on that front pulley. I've seen pants get sucked right in. I've got an extra stock one if you need it. Let me know...
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Midnight_rider
Posted on Sunday, December 11, 2011 - 12:53 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

looking gooood!!!!
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