Rebuilding

[79Intruder]

Getting frustrated with this rebuild. Trying to take off the belly. The rivets are not coming out. Tried to drill them but no success yet. Any help plz. Thanks Marcus.

[mswyka]

Marcus, you do need to drill them out.  I have found that the steel rivets need a really sharp bit.  For the work on the sleds I have been getting my bits from NAPA - NAPA High Speed Steel.  These are the most reliable bits that I have found.  And while I am not saying that it won't take work, keep persevering and you will be successful.

[Invader440]

I've gone to using Cobalt drill bits at work to drill out pop rivets.  They seem to stay sharper longer.

[79Intruder]

Ok thanks guys.

[79Intruder]

Well found a set of titanium drill bits to get the bell pan off, Much easier. Then after I got that belly pan off, only to find the cross bar ( the one the engine sits under ) is broken and some rot spots. Time for some fabrication. I love that part. Hopping to start that in morning sometime. Does anyone know if the holes have be there? Maybe I can get the wife to take some pictures so you have a better understanding. Let you know how it goes...   Keep them alive no matter what it takes...

[kawhead]

sounds like you need a parts sled     thats how the sickness starts   

[79Intruder]

I know where plenty of part sleds are I just don't have spare cash right now.
 

[mswyka]

If you are patient and keep your eyes open, affordable parts sleds will eventually come along.  As far as the holes, I think that you are referring to the triangles in the "x" frame.  They don't need to be there.  Kawasaki took the metal out to keep the sled as light as possible.  It is really there just to keep the bulkhead true.  I think that Kawasaki did a nice job keeping the sled light, but in some cases they are using only the bare minimum to keep things together.  If you wanted to replace it with some sheet steel it would do the same thing but just be a little heavier.

[79Intruder]

Yes I was talking about the x-frame. Thanks for the info mswyka. But this is one of the reasons I am stripping it down. If I would have just rebuilt the engine I would have had more problems. Keep you all posted.

[79Intruder]

This is what i've done to the frame so far. 





and just incase the pictures don't work.... here's a link to my flickr stream... they're the newest two pictures. 

http://www.flickr.com/photos/42071676@N08/

[getmoresoon]

Hi guys!

79Intruder, you've started JUST THE THREAD I need to follow :-)
I have a 1980 Intruder that I bought to restore in 2010 (Life event got massively in the way). And you've just posted the 1st question I was about to ;-).. what about the x-frame, as mine is rotted too.

Hoping to learn lots from everyone here.

[Interceptor398]

Hi guys!

79Intruder, you've started JUST THE THREAD I need to follow :-)
I have a 1980 Intruder that I bought to restore in 2010 (Life event got massively in the way). And you've just posted the 1st question I was about to ;-).. what about the x-frame, as mine is rotted too.

Hoping to learn lots from everyone here.

welcome to the site!

[79Intruder]

To getmoresoon:
Welcome to the sit as well. After I finally got the belly pan off, I just cut the x-frame off. If you chose to replace it you will add some weight, You mite have to weld the new one on. Other than that clean it up the best you can.