Another Virago based project.

That type of paint scheme will look excellent on the tank, it will make it look longer and slimmer, doing a great job Kim 

 on Nigels comments

I have been doing house repairs and going to work, neglecting the bike project lately.

But yesterday I did my first try at painting flames on a gray painted board, and it will look so cool on the bike.

I made a stencil from cutting the flames out in cardboard, and laying it on top of the board, and spraying the inside edges of the stencil. It made a bit of fuzzy edges, because it floated a bit of the surface.

When I do it on the tank, it will be done in either masking paper, or free hand masking with 3mm tape.

Looks ok to me Kim!

  Should look good 

Always liked flames on cars or bikes, you certainly have the skills to do the job.

They look well cool, cant wait to see how that turns out on your ride 

Good looking flames you have there, they would not look out of place on any vehicle.

After painting a board with two different colors of yellow, I decided upon the darker one, and painted the front fender today.



I have decided to do the flames non symmetric by hand, because it just looks weird when it is to evenly symmetrical made.










Then the tank is next, and both parts will get 4-5 coats of clearcoat.

Looking good there Kim!

That will be some beautiful bike, very well done Sir. You have the skills for sure.

 Nice job Kim.

Looks ace,very good job Kim.

all coming together looking great mate keep up the good work

I have spent all day masking and painting the flames on the tank today.

Looking good Kim,   good idea to do the flames freehand, better than perfectly equal, did you use an airbrush to do the flames? 

  your making a very nice job of it 

Doc Cox wrote:

Looking good Kim,   good idea to do the flames freehand, better than perfectly equal, did you use an airbrush to do the flames? 

Yep, I used one of these cheap ones eBay airbrush, and with this small compressor MC90 airbrush compressor, I can use it in the house because it is very quiet.

That looks the excellent, well done. That'll look lovely when it's been clear coated.

I have made a little bit of progress with the bike.

Removed the seat, sissybar, headlight, bars and instrumentation, and made a mockup of some 16" ape hangers.

I also used some wood to see how it would look lowered.

I also decided to convert it to a single carburator setup, and modified the carburator to be able to change the pilot jet, instead of the pressed in fixed pilot jet.

This way I can use an easily available cheap jet from a Delorto carb, to make the adjustment easy.



First you carefully drill out the pressed in jet.



Then make a small brass connector to fit over the old jet tube, with a 4mm thread in one end to screw the new jet in to.







And solder it to the old jet tube.

Nice work on the Carb Kim, Paint job looks good too, The bikes coming along nicely 

Him Kim, coming on steadily looking good, a very interesting mod for the carb, do you have a link for this please, 

Nice one I can see this is going to be a spot on bike

Doc Cox wrote:

Him Kim, coming on steadily looking good, a very interesting mod for the carb, do you have a link for this please, 

Yep, i found the info on the WTF site, but used a smaller diameter jet, that I can also buy locally.

Here is the link.

http://viragotechforum.com/viewtopic.php?f=57&t=31972&p=283053&hilit=second+gen+pilot+mod#p283053

Think that seat is going to be damn hard Kim 

.... an interesting project ......

...... but as Peter says - I'm not sure about that seat !    ....
...... & the rear shocks look a bit 'wooden' to me !

Good one Yam 

Today I picked up the grinder and cut the rear frame from the bike, and chopped the seat down to a solo seat.

I also flipped the rises to push the handle bars a bit forward, allowing them to have more angle towards the rear.

Still not sure about the handle bars, and might end up welding something together myself.

Taking shape! 

I have started on the new intake manifold today, after deciding it would be too expensive to get a finished one.

Even though fiberglass is not the best material to use because of the heat from the heads, I think it will work fine if it is isolated from having direct contact with the heads.

I started by taking some pipe foam insulation, and used some alupex pipe inside to keep the shape, which was made by trial and error.



Then it was wrapped with alu foil, and painted with a release agent.



One layer of fiberglass was put on, and two mounting plates made.



The foam was removed and I started the fitting process.



This is roughly how it will end up looking when the two pipes are joined together.



The carburator will be fitted on the left side, because the front head is slightly to the right, making more room for the carb.

Very interesting stuff Kim, Your talents amaze me   Looking at the material of the two flange shapes reminded me of Boyesen reed valves from back in the day lol.

This is a great thread, very inspirational.

I have been thinking about how to make the rear fender, and decided not to spend the time making a fiberglass from scratch.

So I found a trailer fender with the correct radius and the small lip all around, to match the front fender, and only being 270dkr ~ £26.

I had to make it narrower by about 3cm, because I want to mount it to the swing arm, and it need to clear the frame under the seat, to allow for suspension travel.

It will off cause be painted with flames to match the rest of the bike, and you can see the new ape hangers I found used  

Excellent I like that a lot 

I like the idea, but if I was making a new rear mudguard I would like to see more of my rear tyre, to make it more aggressive. Looking good all the same.

Thx guys.

The position of the fender is not final yet, as I need to raise it to show the same amount of tire all around, and mount the front fender, to have both fenders stopping at the same place on the tire.

I just didn't want to start cutting before I was sure what to do.

I'm also not sure if I should extend the fender braces up in the air, to make a sort of useless sissybar 
It make look and old school together with the ape hangers.

This bike is showing some real potential.

Looking good Kim, the idea for the sissy bar sounds good