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PostPosted: Fri May 04, 2012 5:49 am 
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Joined: Sun Sep 19, 2010 1:19 am
Posts: 713
No rest for the wicked. This Ody will be a graduation gift for my little brother. I got 30 days to finish it. It will get rebuilt roll cage like stock with custom bumper. I will take the Ody all apart and sand the original black paint and rattle can. No time for POR15 prep and all that. It will look nice but just a makeover for the most part. Will Be useing good used parts taking off the FL250's from past restores. I will just clean the gas tank the best I can. Not going to paint that to watch gas eat it off. It will have a side cage and bumper kind of like the ody's in the last pic but no nerfbars. I will be adding a bolt in bar like the FL350's have to keep the roof roll bars from caving in like FL250's do.

Notice how tweaked this cage was. Also notice the steering column is tweaked as well. It took a super hard hit to move that colunm like that. Also to krinkle the cage like that. Pic shows how bent the column is. This Ody does run well and has 148lbs compression. Starts right up.

Be back with another damage report.


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PostPosted: Fri May 04, 2012 6:03 am 
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Joined: Sun Sep 19, 2010 1:19 am
Posts: 713
Also the pipe has been welded for some reason. In the pics that's a bracket that bolts to the frame and the pipe. For some reason they welded the bracket to the pipe. Hack weld at that as well. Also no nuts on the tierod end. Lots of sand pack into all the corners and hiding spots.

The good is that there is little rust. All the bolts are comming out easy without snapping. Wire harnest is uncut and okay. Cables are both good. Both brakes are good. Axle still shows original gold color. Tires are good with okay aluminum wheels. Runs killer. No rust in tank. Although the frame is bent both j-arms and spindles are fine. Real axle bearing are tight. Reduction unit is tight with no leaks. Newer belt. This Ody did come with the tail light but not in pics.

The bad and needing replaced.

Steering column and shaft,tierods,pipe&bracket,and one shock. Seat pan is rusted out. I am out of seat pans so I will fix this one by welding or revit some sheet metal.

Damage report

Bent frame
bent tierod
One bent wheel
Bent bumper mount on frame
Hole busted thru transmission/reduction unit
Pipe has weld job that turn it into near scrap.
Bent steering shaft at pitman arm
Bent steering column

If I did not have a small junk yard of parts this deal would have went sour fast. This ody took a hard hit or fell out of a truck. The frame can be fix if a guy needed to. I have extra frames in good condition. I have only the early model frames though. The only difference is the front bumper bracket the bumper bolts to. It will be faster for me to cut the bracket of this bent frame and weld in onto the good early model frame. Than to try to fix this frame.

The good news is I found some fenders I forgot I had. So now all I need to find is one used red front fender. About $50 on Ebay.

This pic show the pipe. Not sure what this person was thinking. It is what it is I guess. It's not junk but it goes to the back of my parts pile for sure. Some day a person will need this pip.


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PostPosted: Fri May 04, 2012 6:08 am 
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Joined: Sun Sep 19, 2010 1:19 am
Posts: 713
First pic shows the tool I made to fix the frames. It's made from and old J-arm so it fits over the bar perfect. This stops the bar from ovaling when ranking on it. I stick and old 350x axle into the end of the bar for more leverage.

Rest of the pics are just random pics of tonight work. And my growing parts piles. I will be using this frame. It's it great condition.


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PostPosted: Fri May 04, 2012 6:12 am 
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Joined: Sun Sep 19, 2010 1:19 am
Posts: 713
First pic shows the tool I made to fix the frames. It's made from and old J-arm so it fits over the bar perfect. This stops the bar from ovaling when ranking on it. I stick and old 350x axle into the end of the bar for more leverage.

Rest of the pics are just random pics of tonight work. And my growing parts piles. I will be using this frame. It's it great condition.


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PostPosted: Fri May 04, 2012 7:50 am 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22133
Location: Chicago
Wow that's going to be a hand full cant wait to see the finished product thanks for restoring/saving another Odyssey hopefully someone will look at it 30 years from now and be happy someone saved it.


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PostPosted: Sat May 05, 2012 3:32 am 
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Joined: Sun Sep 19, 2010 1:19 am
Posts: 713
hoser wrote:
Wow that's going to be a hand full cant wait to see the finished product thanks for restoring/saving another Odyssey hopefully someone will look at it 30 years from now and be happy someone saved it.


Thanks Hoser. It's going to be hand full but not so bad for I am not going all out on this one. I got lucky I got spare parts or it would of been a huge hand full. I am thinking a few weeks and it will be done. It will look good but be all used parts like bearings and stuff I been saving.


I got both Odys taken apart. I had to put the cage and foot tub back on to make my bumper and side cages.

Image

I am using an early model frame so I had to cut some brackets off the old frame and weld onto this one. On the early models the bumper bolter to the shock mount. Honda changed this in the later (red) models. If the bumper takes a good hit it will bend the shock mount. In this pic you can see the early style mount on the shock tower. You can also see the bracket I cut off the old frame and ready to be welded. Now if the bumper takes a hit it will fold/flex this bracket. And not take out the shock tower.

Image

For the bar that runs out to the front bumper I used both sides from the original Ody bumper. Less work and all the holes and bracket is already welded.

Image

Image

Image

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I have this main bumper bar you see in the pics. And another a little smaller. Not sure what I am going to do yet. Just going to drink a few cold ones and see what I come up with. (Love this part) Still need to make the bars that come from under the ody.


Image

Image

Again this pic gives you an idea what the bumper will look like. I will change it up but this is the basic idea.

Image

Well do the side cages tomorrow. Then it's ready for the mass degreasing and cleaning.


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PostPosted: Sun May 06, 2012 1:48 am 
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Joined: Sun Sep 19, 2010 1:19 am
Posts: 713
I got the bumper done today. I used the parts from an old fl250 beat up bumper I had. By using the bumper I was able to make it without any bending.

Still not done. Going to add some to it.

Some pics


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PostPosted: Sun May 06, 2012 11:03 pm 
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Joined: Sun Sep 19, 2010 1:19 am
Posts: 713
I got the side cages done today. I also added two bars behind the driver head. I will put foam padding on those three bars. Also padding on the side cages and the three bars going down on the side cages. This will protect the drivers head from behind and the sides. Hard to see what I am doing but trying to protect the whole head area with padding. The side cages giving a little more protection while making the cockpit larger. I went with the two bars behind the drivers head for it was a cheap way to add head rest which I was going to buy.

Only bummer is not sure the net will fit with the bars behind the driver head. Sure it will but have not fitted it yet. Fingers crossed. That and your not going to be able to see behind and the sides to good. May need a mirror.

All fab work is done besides the weld up. Once I check the head net it's time to start paint prep for next weekend.

Having my wife hold stuff while I tac weld is always funny. I need to film it one of these days.

Some pics

Edit: I am adding a bar on the roof to the hoop like the fl350's have. Helps keep the top roll bar from crushing in.


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PostPosted: Sat May 12, 2012 3:42 am 
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Joined: Sun Sep 19, 2010 1:19 am
Posts: 713
Been a few days but still chugging along. Got all the parts I am going to use ready. Also today got most cage to bare metal. It should be in paint by Sunday if all goes well. All original colors. This frame was already stripped at one time. So clean up was really fast. Most the time lots of rust under the frame. Also soaked all the parts in degreaser and got them cleaned up.

Even though it is a makeover and not a full restore. It will still look nice and have good used parts. Just the paint wil be rattle cans so will not hold up the best. It will look pretty though.

My brother has about 5 akers to ride on. So it will be well used anyway. If he takes care of it we can always trick it out later.

I really need a red front fender and 3 hole aluminum front wheel. Or nice used stock type front tire. If I can find a good tire I will use steel wheels. If I can find a 3 hole wheel I will use the aluminum ones you see in the start of this thread.


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PostPosted: Sun May 13, 2012 10:13 pm 
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Posts: 713
It was paint day today.My fingers killing me. I thinks it's easier to brush POR15 now with this much rattle cans. I did not paint the gas tank. Rattle can will not hold up and will not look good as soon as you spill gas. I will just polish it up the best I can.

Anyway I think it will look well when I give it to him on grad day. Now the fun part starts. Still need to paint the Engine, pipe and polish the reduction unit though.


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PostPosted: Sun May 13, 2012 10:24 pm 
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Joined: Wed Jan 21, 2009 10:11 pm
Posts: 2939
Location: houston
Looking good! They sell a tirgger attachment that will hook right onto a can of spray paint,I think I picked mine up at walmart,a lot easier on the finger :-)


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PostPosted: Wed May 16, 2012 5:38 am 
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Joined: Sun Sep 19, 2010 1:19 am
Posts: 713
About 10 minutes with brush and POR15 Marine Clean. Marine Clean is amazing stuff. I used maybe a pop can worth on both Engine and reduction unit. I get it for $12 a quart and mix it 5 to 1. So five quarts.

I need to go back and get the fins around the exhuast port with tooth brush. It did miss some in the thick stuff. I spent only about 10 minutes with brush and 5 with pressure washer. Before I used marine clean it would take me hours cleaning up dirty greasy Engine. Time saver for sure. Also the clutch cam and spring. Those are hard to clean as well. It get all that junk out of there even when the brush cannot get to it.

Here is some info on the stuff.


MARINE CLEAN™ is a complex mixture of organic & inorganic
chemicals. It is non-toxic, biodegradable, water-based, and has
no noxious odors nor chlorinated solvents. It doesn't contain any
petroleum products and has no fl ash point. Marine Clean represents
a revolutionary breakthrough in cleaners, degreasers and
dispersants.

Use MARINE-CLEAN™ for cleaning and degreasing machinery
parts, turbine blades, diesel engines, compressors,
transformers, bulkheads, deck plates, bilge areas; removal of oily
deposits found in closed systems such as air conditioning, boiler
tubes, compressor lines, heat exchangers and coils; removal of
light distillates, mineral oils, heavy grease, degreasing all metal
surfaces, plastics, wood, fi berglass, painted surfaces. Always
wear eye protection and rubber gloves when using Marine Clean.



And the pics of the job. Also skip to 1:20 in the vid it shows some Marine Clean on an Ody frame.

http://www.youtube.com/watch?v=AIbpEe1Hagk" .".." .".." .".." .".." ."..

This Engine has like new piston and walls. I will post pics in next update. Both bottom bolts were stripped on the bottom of the exhuast manifold. Blowing black all over. I see green gaskets as well. Really happy with condition.

CAN YOU FIND WHAT'S NOT RIGHT IN THE PICS ABOVE? FIND THE PART THAT IS NOT INSTALLED RIGHT?


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PostPosted: Thu May 17, 2012 2:32 am 
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Posts: 713
Now the fun part starts. I love this part of the build.

Makeover is comming right along now. Nothing special just trying to make a dependable Ody.

Got a little water on the piston washing the Engine. Piston looks different than what I see on my other ody engines.


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PostPosted: Fri May 18, 2012 1:45 am 
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Posts: 713
I switched out the old OEM bearing for a nice used sealed bearing.(from ATC350X) Also painted the foot tub and cleaned up the gas tank. I did not want to paint the tank with rattle can for gas would just eat the paint away. So I just cleaned it and left the original paint on it.


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PostPosted: Sat May 19, 2012 12:31 am 
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Posts: 713
Moving right along.


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PostPosted: Sun May 20, 2012 10:05 pm 
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Posts: 713
Got a lot done today. It's got good spark as well. All the hard stuff is done now. Should be starting it soon.

Had to buy a $60 aluminum wheel shipped as well. So far I have $90 in this makeover. $60 for the wheel and $30 in paint. Having good spare parts helped me out lots though on the pocket book. If I did not have the parts on hand it would of cast about $150 to replace them if I shopped well.

Some pics


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PostPosted: Tue May 22, 2012 2:18 am 
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Posts: 713
Got a good chunk done today. I need this finished by this Friday. Going to give it to my brother at a weekend family camping trip this Saturday. I will get some pics of that as well.

Left to do

mount wheels and tires
Seat
Headlight
fuel filter
air filter
foam padding
exhaust baffle & springs
polish wheels
Restore fenders
change tire to new wheel
roll bar bolts

Should have it done in a few days now.


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PostPosted: Wed May 23, 2012 12:19 am 
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Posts: 713
Had to pull my nephews Ody steering wheel kart out today and get it ready for this weekend. Fired right up and ready to do. Change the oil and lubed the chain. Cleaned the clutch as well. Still need to pull the ATC110's out and get them ready.

The Ody is almost done. Getting close now. Right down to the wire.

Some pics of my nephews kart I built him last year. He is handicap so it I used an FL250 wheel. It is Yerf Dog kart but I added the nerf bars and wing. 6.5 HP honda clone with dual tanks. Comet Clutches with pipe. It goes really good for a kart. Lots of torque. Also added the lights and flashing LED's with music box. I upgraded the seat belt as well.


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PostPosted: Thu May 24, 2012 1:33 am 
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Got the seat in and a bunch of little stuff like cotter pins and fuel plumbed up. Rear wheels mounted as well.

In the last two pics you can start to see the built in head rest I made. I added the two extra bars on the main hoop. Then built this side cages with the three down bar to add pads for protection. My sled Ody has a head rest I really liked it. Was in a hurry to get this done so I came up with this idea. IDK if it's safer with it or not. But my thinking is it's netter than nothing I hope anyway. There will be pads on the side hoop bar as well. That whole section will be pads with no red. I got to have this done by Friday for this weekend.

I think after I give it to my brother. We will make a set of sick nerf bars that he can make himself with my help.

Big question though. Do you see any saftey concerns with side cages? I will post pics in next post of how they are connected. I used grad 8 bolts to connect them. I would hate to see them bust off and hit the driver in the head. They would bend first right?


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PostPosted: Thu May 24, 2012 1:40 am 
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Fab pic of side cages. Hmmm I can only find this one. But you get the idea. Welds are good and strong. It would have to break the bolt and the tab for the side cage to go in and hit the driver.

Tell me what you think good or bad.


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PostPosted: Fri May 25, 2012 11:05 pm 
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She is done and loaded ready to give it to my brother tomorrow. Still need to do seat belts and rear skid plate. I am doing that tonight as soon as the rain stops. Foam padding as well if I get to it.

Also loaded up the yellow Ody and the nephews gokart. Should be a fun weekend until I get the gas bill that is.

Also Ody started right up and runs killer.


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PostPosted: Sat Jun 02, 2012 3:54 pm 
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And it is my little brother Ody now.

Lucky young man. He got this Ody from me. My parents got him a 1943 miltary Jeep with hard top.

I did not get the new aluminum wheel in time so I borrowed a set from my other Ody's. It does have matching tires and wheels though.

His firt ride he hit a wire fence and ripped the padding.


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PostPosted: Sat Jun 02, 2012 11:45 pm 
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Location: houston
Lucky kid,a jeep and an ody,he needs to have a smile on his face,he doesnt look happy in that pic,I'd be grinning ear to ear.You do very nice work


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PostPosted: Wed Jun 06, 2012 1:17 am 
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redskinman wrote:
Lucky kid,a jeep and an ody,he needs to have a smile on his face,he doesnt look happy in that pic,I'd be grinning ear to ear.You do very nice work


LOL, Yah it was right after he ran into fence on very first ride. We were making fun of him when taking these pics.

In a few weeks I am going to help him make some nerf bars. And maybe an electric starter. Also finish the lighting. I notice one j-arm is bent or something. So we will need to replace that or fix the main bar on the frame. Frame looks good though so perhaps I got a bent J-arm I did not notice. I did notice something was wrong but I ran out of time.

This will be perfect for him amd maybe I can get him into mechanical things. Right now everything is Military on his mind. My parents have 6 akers where he lives. This Ody will get some good use for sure.

It seemed like it was not stable with those large tall tires. When I first took it out I ran it pretty hard test driving it. It just seemed like I was on two wheels more than my other Odys with normal tires. I am going to switch them all out for stock style tires. For some reason I like the dimple style tires.

The good news is this car rips. The Engine has more power than my others Odys as well. Not sure how tires size is factoring in. But it has great power. Remember the Engine was near new. It has a deeper sound as well. Probably a larger piston for sure. My dad said the Engine semms like it runs harder to me for the aluminum wheels let it rev better. Maybe this is what I am feeling power wise. I got aluminum wheels on my Blue Ody but I have not even took it out yet. Same with my Yellow Vintage Racer.

And he is still typing?????

Next project it going to be nephews gokart that eeds the seat fix to fit his handicap. Then I have these two 1982 Yamaha DT100 enduro's. His and hers if you will. The HER part is so I get to build them with little slack from the wife. This will both be street legal with all the lights to bring them back to original. I have all the parts for both bikes already. This will be camp bikes and bikes to ride into town or coastel towns while we are camping. They gotthe power to do it safe but yet easy to start and great for woman.

PO wanted it to look like a dirt bike. So what did he do? He cut all the wires off, even right cut thw wires to all the controls on the grips. Hand to buy another harnest and controls. Also another rear wheel for one of the hubs were broke. The good thing it they took all the original lighting in mint condition and pit it in a bucket. So I got all the lights and even foot pegs in perfect condition. I am going to leave the tanks in original paint. But restore everything else. I will POR15 black the frame and swingarm. And use POR15 Whitcote on the rear fenders. I can brush POR15 on and I think it's tougher than PC. I can paint both these bikes for about $75 and have high quality paint job. Or a really tough paint job that looks good anyway. I painted a Moped with it for the paint was beat to hell from riding on the front of my travel van. What I like about por15 is it chemical resistant. So gas has no effect on it. Even two stroke oil just wipes right off.

If por15 hardnose red matches close to honda red I would recomend it to paint an fl350 or fl400 with it. My reason for this are it's supper tough paint. You do not need a paint booth and tools. It's cheaper than PC and easy to fix repairs. You brush it on or spray. Regular por15 black needs a rusty base to get the legendary por15 toughess. But Hardnose paints does not. Hardnose does not need a top coat loke por15 black. Por15 is a product you need to follow intructions very good. Do not skip out on the 3 step cleaners.

I am not a paint expert and never painted anything but with rattle cans. But with por15 paints I call myself an expert from messing and testing the stuff. If got any questions just ask. I do know whats in it or how it works. But painting with it I can help you out. For those that do not know of por15, do some googling. It's a amazing stuff. Most the stuff you will read in por15 black though. For your fl350's and pilots you would look into the hardnose paint line they have. The moped below id hardnose light red.

Thanks for letting me go off on my long post.


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