My '78 GL Restoration


Information and questions on GL1000 Goldwings (1975-1979)
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tomk1960
Posts: 18
Joined: Thu Sep 27, 2018 8:19 am
Location: Worcester, MA
Motorcycle: 2010 Kawasaki Nomad, 1986 Honda VFR750F, 1983 CB1100F Super Sport, (3) 1978 Honda GL1000, 1974 CB750 Four

My '78 GL Restoration

Post by tomk1960 »



I bought this bike nearly 3 years ago with the intentions of digging in almost immediately.


It ended up getting pushed to the back of the shop while I finished my '83 CB1100F resto-mod and then my son's stock CB1100F. Already into my next build, I stopped in my tracks and said that it was time to get this one done. I had been powder coating parts for it over the past couple of winters, but everything was boxed up on the shelf. Most of the new parts I needed were also up on the shelf, so it was just a matter of execution. The following was done to the bike:

1) Powder coated the wheels metallic gold to go with the pin stripes and burgundy paint. (the silver Comstars never looked right)
2) Mounted and balanced new tires and tubes


3) Had the brake rotors surface ground and cross drilled, then PC'd the centers to match the wheels
4) PC'd the front and rear calipers and masters and rebuilt them. (Front master is from an '83 CB1100F)
5) PC'd the swingarm, footpeg hardware, battery box, and fork legs, then rebuilt the front end
6) Discovered that the early 80's dual piston front calipers are an easy bolt-on upgrade, so I took that route


7) Installed a sleeker CB900C front fender - an easy bolt-on upgrade
8) Installed new Galfer braided SS brake lines, bled the system
9) Installed 3 piece handlebars from an '83 CB1100F Super Sport. Lower and more comfortable
10) Had the carbs professionally overhauled by Mike Nixon
11) PC'd a good fuel tank and replaced the leaky one
12) Installed Harley take-off mufflers
13) Using a Venhill universal throttle cable kit, made up new cables to accommodate the lower bars
14) Adjusted valves, then installed new gaskets and PC'd covers/badges
15) Installed new Gates belts and PC'd covers
16) Spray painted the pumpkin to match the wheels
17) and plenty more that could fill another page...

Here are a few more bling pictures. Here's a shot of one of the new shocks installed as of this morning:


Right side muffler bracket that I made out of local hardware store bar stock. A couple bends in the vice, a couple of holes drilled, and after powder coating, nearly invisible back there.


After valve adjustment, I finally installed the valve covers that I PC'd at least a couple of years ago.


I finally fired it up for the first time Sunday evening and it sounded good. I need to warm it up good so that I can burp the radiator, set the idle speed, and sync the carbs. The starter solenoid is shot and I had to short the terminals to start the bike. A new one is on the way, along with a modern 30A blade fuse pigtail that I'll splice in to replace the old metal dogbone fuse. Hopefully I'll have the couple remaining electrical issues sorted by the weekend so I can take it out for a little ride around the block.

I heard that you all like pictures, so once the bike is out of the shop and in the driveway, I'll get a nice shot of it finished.

This was what I call a "mild" restoration. The bodywork was in nice shape - not perfect, but after some good polishing it will look great. The engine didn't come out since it has low miles on it. My goal was to bring it back to good, safe operating condition and RIDE it. If the weather holds up, I might just get to do that for a month before it's time to store for the winter.


fire_strom
Posts: 6
Joined: Sat Nov 14, 2015 12:23 am
Location: Durango
Motorcycle: Future Goldwinger

Re: My '78 GL Restoration

Post by fire_strom »

Very interesting stuff. Was there any complication with powder coating the wheels, rivets and different pieces and all? Was there any modification required for the bc900c fender? I tried putting a Virago fender on mine and to was a total junk show. The cb900c would be perfect for the direction I want to go with my '78 too.
How do I subscribe?
-G
fire_strom
Posts: 6
Joined: Sat Nov 14, 2015 12:23 am
Location: Durango
Motorcycle: Future Goldwinger

Re: My '78 GL Restoration

Post by fire_strom »

What is the story with the shocks?
-G
User avatar
Fred Camper
Posts: 1339
Joined: Sun Aug 16, 2009 9:15 pm
Location: Metro Detroit, MI
Motorcycle: 1977 GL1000, 1976 LTD GL1000

Re: My '78 GL Restoration

Post by Fred Camper »

I too would like to know more about the rear shocks and front fender. Looks like a fine ride. Great Craftsmanship.
tomk1960
Posts: 18
Joined: Thu Sep 27, 2018 8:19 am
Location: Worcester, MA
Motorcycle: 2010 Kawasaki Nomad, 1986 Honda VFR750F, 1983 CB1100F Super Sport, (3) 1978 Honda GL1000, 1974 CB750 Four

Re: My '78 GL Restoration

Post by tomk1960 »

fire_strom wrote: Tue Oct 16, 2018 9:42 pm Very interesting stuff. Was there any complication with powder coating the wheels, rivets and different pieces and all? Was there any modification required for the bc900c fender? I tried putting a Virago fender on mine and to was a total junk show. The cb900c would be perfect for the direction I want to go with my '78 too.
How do I subscribe?
-G
I've powder coated quite a few sets of Comstars, including a bunch of the "boomerang" style that were used on the European and Canadian bikes. They aren't too bad to too, but it's time consuming. I have to knock out the bearings, plug up the hubs, clean them up a bit, then media blast with aluminum oxide. Blasting is tedious due to all the visible surfaces that need to be done. The wheels are left completely intact during the whole process. After washing and outgassing, they get the base coat of metallic gold and a full cure. The gold can be a little tricky to lay down with all the tight spots, but preheating the wheel helps. After cooling, it gets a topcoat of super high gloss clear which lays down pretty nicely.

The 900C fender is a direct bolt-on. No drilling, no mods, nothing. It couldn't be any easier and I think it looks a whole lot better.

fire_strom wrote: Tue Oct 16, 2018 9:44 pm What is the story with the shocks?
-G
Those are brand-new EMGO shocks designed for the GL1000's. Part number is 17-05534 and they're priced around $120 shipped for the pair on eBay. Supposedly they're a little better than the stock shocks, but nothing like the ones that cost 3-5 times as much. I haven't ridden the bike too much yet, but they seemed a bit stiff. I have to check to see how I have them adjusted - it might just be a matter of a little tweek to get them right.
Fred Camper wrote: Tue Oct 16, 2018 10:34 pm I too would like to know more about the rear shocks and front fender. Looks like a fine ride. Great Craftsmanship.
Thanks very much. I love how the bike looks, but not how it runs...yet. I think I might have a timing problem. it stumbles and runs rough under load. I replaced the belts 3 years ago and I'm wondering if the timing might be off by a tooth. If adjusting timing the normal way doesn't fix the problem, I'll pull the radiator and check the timing marks on the gears to make sure they're correctly lined up.

Here are a couple more updated pics of the bike:







fire_strom
Posts: 6
Joined: Sat Nov 14, 2015 12:23 am
Location: Durango
Motorcycle: Future Goldwinger

Re: My '78 GL Restoration

Post by fire_strom »

Thanks so much for the updates. Looks great!
-G
tomk1960
Posts: 18
Joined: Thu Sep 27, 2018 8:19 am
Location: Worcester, MA
Motorcycle: 2010 Kawasaki Nomad, 1986 Honda VFR750F, 1983 CB1100F Super Sport, (3) 1978 Honda GL1000, 1974 CB750 Four

Re: My '78 GL Restoration

Post by tomk1960 »

One thing I forgot to mention in regards to PC'ing the wheels. You'll need a good variable voltage gun to do both coats. A single voltage hobby gun won't work and it won't have the right nozzle for getting into the tighter spots either.
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Fred Camper
Posts: 1339
Joined: Sun Aug 16, 2009 9:15 pm
Location: Metro Detroit, MI
Motorcycle: 1977 GL1000, 1976 LTD GL1000

Re: My '78 GL Restoration

Post by Fred Camper »

Appreciate all the detail and knowledge shared.
Rockdog
Posts: 36
Joined: Mon Jan 01, 2018 12:15 pm
Location: Newberg,OR
Motorcycle: 2002 honda goldwing gl1800.... 1978 gl1000

Re: My '78 GL Restoration

Post by Rockdog »

Nice looking 78. I've got one also and have been thinking of getting a shorter set of handlebars. I was wondering where and what kind of bars you used for your build?
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Fred Camper
Posts: 1339
Joined: Sun Aug 16, 2009 9:15 pm
Location: Metro Detroit, MI
Motorcycle: 1977 GL1000, 1976 LTD GL1000

Re: My '78 GL Restoration

Post by Fred Camper »

My 1977 came with bars higher than the 1975 model and since I like the earlier bars I purchased a Superbike bar also called euro bar from Emco I think. Had to machine the oval centerline hole to route the wiring but it did work just fine. Had to shorten the throttle and clutch cables and also the front brake hose. Well worth it for me.
tomk1960
Posts: 18
Joined: Thu Sep 27, 2018 8:19 am
Location: Worcester, MA
Motorcycle: 2010 Kawasaki Nomad, 1986 Honda VFR750F, 1983 CB1100F Super Sport, (3) 1978 Honda GL1000, 1974 CB750 Four

Re: My '78 GL Restoration

Post by tomk1960 »

Rockdog wrote: Sat Oct 27, 2018 8:44 pm Nice looking 78. I've got one also and have been thinking of getting a shorter set of handlebars. I was wondering where and what kind of bars you used for your build?
I used a spare set of 3 piece adjustable bars from an '83 CB1100F that I had in my stash. They aren't the easiest to find, but try eBay. The bars used on the VF1100 Sabre are similar and might be easier to find. Otherwise, EMGO sells lots of options for bars, so check out their catalog: http://emgo.com/images/pdf/2017Handlebar.pdf

I needed shorter throttle cables, so I bought a Venhill universal kit and made them up to fit. When I was setting up the brakes and about to order new SS lines, I took measurements and got a custom length top line - the one that goes from the master to the splitter. Those came from Galfer. I'm a dealer for all three lines, so if you need any of those parts, I can get you good pricing.

These bars are just the right height and are very comfortable. They also look a lot sportier than the long mini-hangers that came with the bike.
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Fred Camper
Posts: 1339
Joined: Sun Aug 16, 2009 9:15 pm
Location: Metro Detroit, MI
Motorcycle: 1977 GL1000, 1976 LTD GL1000

Re: My '78 GL Restoration

Post by Fred Camper »

If anyone wants to buy new front brake hoses, you can use a dual banjo bolt and eliminate the splitter. Removing the splitter makes the system easier to bleed and you have less joints in the system. The splitter is no longer used on modern bikes. Buying two SS hoses instead of three costs less as well. Be sure to ask for the dual banjo bolt.
kndw
Posts: 132
Joined: Sat Jun 19, 2010 2:56 am
Location: Driebergen, Utrecht
Motorcycle: 1976 GL1000 Gran' Luxe

Re: My '78 GL Restoration

Post by kndw »

Very nice! Can you also give some more info about the front brakes? So these are refurbished discs with calipers from what bike exactly?
tomk1960
Posts: 18
Joined: Thu Sep 27, 2018 8:19 am
Location: Worcester, MA
Motorcycle: 2010 Kawasaki Nomad, 1986 Honda VFR750F, 1983 CB1100F Super Sport, (3) 1978 Honda GL1000, 1974 CB750 Four

Re: My '78 GL Restoration

Post by tomk1960 »

kndw wrote: Mon Oct 29, 2018 3:59 am Very nice! Can you also give some more info about the front brakes? So these are refurbished discs with calipers from what bike exactly?
Yes, the brake rotors (stock '78 GL1000) were surface ground and cross drilled by TrueDisk. You can reach Tom Tokarz at www.truedisk.net. Prices are reasonable and he turns them around quickly.

The front calipers can be found on numerous Honda models made in the early-to-mid eighties. Part numbers are 45101-MA3-006 (left) and 45201-MA3-006 (right). The caliper brackets are a little harder to come by, but are available out there used. The brackets I used come from the 81/82 CB750F and CB900F. I believe that the brackets used for the CB900C and CB1000 will also work, but I can't confirm without having them in hand. They will definitely work with the calipers, so it's just a matter of the mounting holes on the fork legs lining up.

I have lots of spare calipers in stock and can help you out with those if you decide to make the upgrade. I probably have at least one more set of caliper brackets on hand too. The stock brake lines that go from the splitter to the calipers are the correct length, although I would highly recommend going to SS braided lines as part of the upgrade.

The beauty of this is the fact that they bolt right on with no mods needed. You can't beat that!
kndw
Posts: 132
Joined: Sat Jun 19, 2010 2:56 am
Location: Driebergen, Utrecht
Motorcycle: 1976 GL1000 Gran' Luxe

Re: My '78 GL Restoration

Post by kndw »

tomk1960- I have tried sending you a PM, but there s nothing in my 'sent' folder. Did you get a message?
tomk1960
Posts: 18
Joined: Thu Sep 27, 2018 8:19 am
Location: Worcester, MA
Motorcycle: 2010 Kawasaki Nomad, 1986 Honda VFR750F, 1983 CB1100F Super Sport, (3) 1978 Honda GL1000, 1974 CB750 Four

Re: My '78 GL Restoration

Post by tomk1960 »

kndw wrote: Tue Oct 30, 2018 9:27 am tomk1960- I have tried sending you a PM, but there s nothing in my 'sent' folder. Did you get a message?
Ksander,

Your second PM came through and I have responded. Not sure why the first one didn't make it...
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Asphaltmaniac
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Re: My '78 GL Restoration

Post by Asphaltmaniac »

Good work looks sharp!!!


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