Check....check....check...

Progress! 

Much has happened in the last two weeks. The frame and swingarm powdercoating is complete and looking FINE! Forks have been rebuilt with all new seals and fresh 10W fork oil, the steering stem bearings have been upgraded to modern tapered roller bearings, and just look at this...

 

 

It's starting to look like a motorcycle again!

 

Upper and lower outer bearing races installed into the head tube for the tapered roller bearings (lower shown):

New bearings installed on the stem - still need to be packed with grease (although I need to remove the lower bearing again to install a 1-2mm spacer that I forgot 🫤):

Forks disassembled and thoroughly cleaned inside & out, the aluminum cases were wet-sanded w/400 grit to clean up the trail rash, fork tubes were checked for straightness (all good 👌👌), and finally rebuilt with all new seals/rings and the appropriate amount of fresh 10W fork oil:

Also, I finally picked up a proper shop manual:

And finally, for now, the front brake drum/hub was refinished. I knocked out the old bearings and got the new bearings (Tusk brand) packed full of grease, to be installed once the paint finishes curing. Prepping and painting it wasn't as difficult as I expected, especially considering the fins, though I definitely need some serious airflow in the garage if I'm going to keep doing this...

A mild soapy solution, a toothbrush, and way too many shop towels took care of the loose grime on the exterior painted surfaces. After ensuring it was totally clear of dirt and grime, the paint was roughed with 220 grit sandpaper and then cleaned and rinsed again, before primer was applied:

While waiting for that to set up, I went inside to grab a drink and a bite to eat. After my short fumigation recovery meal break, the drum was painted using Krylon "Satin Black". Here's a shot of the still-drying XR500 drum compared to the donor XR250 drum that donated its 23" wheel hoop (note the lack of cooling fins on the 250 drum):

Mmmmm.... Satin black was a good choice. Yes. Very, very good:

Stay tuned....

Tax Time Teaser

Well, it's certainly been a minute. Time for an update.

The frame and swingarm have both been stripped completely bare of parts, most grease, and some paint. After calling around, I ended up going with Full Blown Coatings in Murray for sandblasting and powdercoating, as they do both services in-house, have done a lot of motorcycles in addition to their other work, and appear to be very highly-rated. I was quoted $300, finished with their in-house glossy black, which I think is a pretty good deal in the current economy. They seem to know what they're doing.

Final photo before blasting and coating:

On the "hurry up and wait" front, it's currently tax season here, which means PARTS PARTS PARTS! Let's just go down the list:

Parts from Honda:

• Enough seals and o-rings to rebuild both front forks
• Oil seals for the chain tensioner bracket
• Swingarm pivot tube grease seals
• Rear wheel tensioner bolts/nuts
• Fuel tank cushions

NOS/aftermarket replacements:

• Honda swingarm pivot tube bushings
• New front/rear tire tubes and strips
• Brand new front/rear spokes and spoke nipples from Buchanan's Spokes
• Brand new front/rear Bridgestone Trail Wing tires in sizes 3.00-23 & 4.60-18

Upgrades (Factory and aftermarket)

• Custom 7" side-mounted single round headlight from 4into1
• 1979-1981 XL500 stator/alternator (higher output, bolt-on upgrade)

For the new headlight, I went with the classic "70s Honda" look with the glossy black bucket and chrome ring. I debated heavily on getting a grill for it, and I'm kinda regretting not getting one. I'll think about it.

New tires! What a size difference:

I've also acquired a few new tools, including a bench vise and ultrasonic cleaner. Both have already paid for themselves in time and effort saved alone.