It all started a year ago! Just a tidy up but then........

Discussion in 'Full Rebuilds' started by Jgp2004, Sep 23, 2018.

  1. Jgp2004

    Jgp2004 Member

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    Hello all,

    This is really my first proper post on here, Ive been a member for awhile now but in the back ground learning and taking in all the brilliant info on this site..

    The names Jonno im from the UK.

    And heres my story of my 2004 Blaster which i got as a little project but since then its become a big project as ive got abit carried away!

    It started when one day i decided to strip it to clean it up.

    Im not gonna bore you with essays just quick info and pics!!!
    We all love pics..

    I started by tearing it down to give me an idea of what i needed to do.
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    Once Id done that i found lots and lots of issues with it that needed doing. Thats when i decided i was going to fully restore it and improve it.

    The first thing i did was take the frame and components to be shot blasted to remove all the poor hand paint work the previous owner had done. After that i had to repair some damaged bolts and broken engine mounts

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    Once id done them few bits it was time to paint all the parts up to get them all looking fresh!

    A little primer
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    Then on with the paint
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  2. Jgp2004

    Jgp2004 Member

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    Next step was to start to refurb other components before i start to put it all back together.

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  3. Jgp2004

    Jgp2004 Member

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    Then after id done enough to get me started i decided to clean and rebuild the main part the engine..

    New clutch
    20180923_233652.jpg

    Head removed and cleaned and refitted with new gaskets
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    Once id done all gaskets and piston and oil seals i fitted it all back together and then started to clean all the outside

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    Last edited: Sep 23, 2018
  4. Jgp2004

    Jgp2004 Member

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    Next step was to start to fit it up and refurb more parts along the way.

    Firstly new bearings and swing arm fitted together and grease nipple added..

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  5. Jgp2004

    Jgp2004 Member

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    Next step was to start to fit it back up.
    Along the way cleaning and refurbing parts and fitting new dust covers and bearings and brake pads. And various other parts.

    20171228_133627.jpg 20171228_140527.jpg 20180103_181643.jpg 20180105_092856.jpg 20180303_170132.jpg IMG_20180419_074206.jpg

    Starting to look like a quad again. Still lots more work to be done.
     

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  6. Jgp2004

    Jgp2004 Member

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    I cleaned all the hubs up and painted the hgs exhaust with vht paint.
    I also stripped the whole wiring loom and rewired it to except a battery by floating the earth on the stator and added all road legal lights like indicators and brake lights also a acewell speedo. Also modified a set of new levers to work with the standard parking brake. Ive removed the tors and i also removed the oil pump when rebuilding the engine so now its going to be premix. I did the carb mod and added a air fuel mix screw.
    After that i moved the quad to my shed to carry on fitting it up.
    I refurbed my wheels and put the tyres on.
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  7. Jgp2004

    Jgp2004 Member

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    Ive now added a banshee axle and modified a set of raptor heel guards to suit it.

    Ive put all fresh brake fluid in and brakes work perfectly
    And ive tested all the lighting and it works perfectly (pics to come)

    This is currently where ive got to todate
    All left to do really is fit the wheels and finish prepping and painting all my fairing up and finally finish fitting it up. Also ive modded a hgs exhaust i had to fit (pics to come).

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  8. Jgp2004

    Jgp2004 Member

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    Thats were i am to date. Ive probably missed lots of bits ive done. But basically ive so far done a full nut and bolt rebuild. It started as a clean up but now its turned into a full restore.

    Hope u enjoy the pics.

    Ill be posting more as i go along and one day the finished article will be posted!!
     
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  9. Tankbuster

    Tankbuster Member

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    Nice job!!! I would have loved to restore my 88 Blaster, but have money tied up in an old Goldwing project. Again, Great job!
     
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  10. Jgp2004

    Jgp2004 Member

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    Thanks ive put alot of time and effort in and theres more to come!!
     
  11. Blaner

    Blaner Your Friendly South African Ambassador

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    Awesome, love the bog roll between the balljoints, good idea.
     
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  12. Jgp2004

    Jgp2004 Member

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    Did a little bit more today. Tidyied up the wiring for the battery and tested my speedo it all turns on with the ignition.
    Also fitted the rest of my exhaust.
    I used a HGS silencer i had lying around in my shed fabricated a pipe from the original tail pipe to suit. Im happy with the result fits well along with my HGS front pipe.

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  13. Jgp2004

    Jgp2004 Member

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    A little more progress earlier.
    Fitted my new skid plate had to open up the mounting holes abit due to larger rear sprocket but no biggie also fitted the speed sensor for the acewell..and just a cheeky shot from the rear.

    Im happy with how it looks.
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  14. 79 bronco

    79 bronco Moderator & Self Custom Psycho Staff Member

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    79 bronco Moderator & Self Custom Psycho Staff Member

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    79 bronco Moderator & Self Custom Psycho Staff Member

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    79 bronco Moderator & Self Custom Psycho Staff Member

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