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Above 1200 Sq/FT The ASYLUM - Happy 40th Birthday to Me! (Est. 2005)

Wokspaces above 1200 squarefeet.
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shopnut

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MY YAMAHA RZ500 IS BACK ON THE ROAD AGAIN… (Part 2 of 6)

Even though some spots will never be seen when the bike is together, I can’t stand paint overspray, even if it is seen only during maintenance chores. The underside of the tank and tail bodywork got some fresh paint.

3712-099-RZ500-Gas Tank-01.JPG 3713-116-RZ500-Gas Tank-39.JPG

3714-151-Tail-Bodywork-08.JPG 3715-153-Tail-Bodywork-14.JPG

(Continued)
 
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shopnut

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MY YAMAHA RZ500 IS BACK ON THE ROAD AGAIN… (Part 3 of 6)

These are all the kickstand parts.

3716-186-RZ500-Kickstand-17.JPG

Rear brakes gets a full rebuild and repaint.

3717-196-Rear-Brake-13.JPG 3718-213-Rear-Brake-86.JPG

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This is the clutch lever. Please note the ball bearings in the pivots.

3720-225-RZ500-Clutch-06.JPG

The shift lever pivots were worn, so I found a decent spare.

3721-335-RZ500-Shifter-08.jpg

Some cable guides keep things under control.

3722-425-RZ500-Front-Reflectors-Brake-Hose-Guides-11 (Throttle Guides).jpg

(Continued)
 
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shopnut

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MY YAMAHA RZ500 IS BACK ON THE ROAD AGAIN… (Part 4 of 6)

The fuel system took the most amount of work and I started on this back in August of 2018.

Here is the vacuum actuator fuel valve. Parts had to be sourced from the UK.

3723-256-Fuel-Valve-Rebuild-07.jpg

Like the DR650, it received a full carburetor refreshing, but this time there were 4 of them to deal with so progress was slow.

3724-Carbs-Reassembly-Left-Side-01 (Left-Bottom).jpg 3725-Carb-Reassembly-All-05.jpg

3726-291-Carb-Reassembly-All-01.jpg

I made some custom carb slide needles on the lathe. Grooves that needed to be cut were only 0.020” and rather than pay extra for a special grooving tool, I managed to to the job with a thin kerf jigsaw blade. How redneck is that!

3727-284-Carbs-Needle-Mods-03.jpg

Here are the carbs back on the V-4 engine, 2 on one side, 2 on the other. This twin crank engine is quite unique.

3728-300-Carbs-Final-Installation-07.jpg 3729-301-Carbs-Final-Installation-08.jpg

(Continued)
 
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shopnut

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MY YAMAHA RZ500 IS BACK ON THE ROAD AGAIN… (Part 5 of 6)

The electrical system was a bit ratty, so quite a bit of time was spent on it.

A new ignition switch was sourced and rekeyed to maintain the matching key to the fuel cap and helmet lock.

3730-060-RZ500 E02 Ignition Switch Repair-11.JPG

Handlebar switches were totally disassembled, cleaned, and painted.

3731-354-RZ500-Electrical-04 (Turn Signal).jpg

This B-style crimper worked nicely on the old bullet-style connectors.

3732-383-RZ500-Electrical-41 (Front Turn Signals).jpg 3733-384-RZ500-Electrical-43 (Front Turn Signals).jpg

Relays and fuses were just cable-tied into a ball, so I made a dedicated mount up in the front fairing.

3734-364-RZ500-Electrical-35 (Front Cowl).jpg

Replacement parts for this obscure bike are hard to come by and pricy when you find them. Since I am not after perfect originality on this restoration, I can pick up low cost alternatives. This coolant overflow bottle for instance, cost $4 when the correct OEM version would have set me back $100.

3735-442-RZ500-Coolant-Overflow-Bottle-24 (Painted).jpg

While rebuilding and enhancing this bike, it has been wonderful to have cabinets full of hardware to pull all the little bits and pieces from. Here is my selection of M6 fasteners, for instance.

3736-Luxor-Cabinets-947.jpg

(Continued)
 
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shopnut

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MY YAMAHA RZ500 IS BACK ON THE ROAD AGAIN… (Part 6 of 6)

In November of 2018, I was finally at the point I could restart the old girl. Some fuel line routing issues were easily remedied, and she fired right up. Hearing that V-4 2-stroke for the first time in 6 years was the incentive I needed to wrap it up by the end of the year, for Phase 1 anyway.

3737-Starting-04.jpg

And here the bike is, $923 later after its purchase, all finished up with what I called PHASE 1. What a joy to ride! You better be hanging on if you see that tach go over 6,000rpm! It begs for high RPM flying, but it’s surprisingly well-mannered at low RPMs for a 2-stroke GP race-replica bike.

3738-RZ500-Overall-21.jpg 3739-RZ500-Overall-37.jpg

Where do I go from here? Well, Phase 2 of course! I started this little story with a list and that is where I will end it as well today. I’ll give some updates from time to time and I finish polishing out all the rough edges of this little gem.

3740-X64-RZ500-Service-List-Phase2.JPG
 
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jbmatth

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Great job on the RZ500, I'm sure it was nice to get it back on the road after so many years. Looking forward to some more of your future projects and updates.

JB
 

JCQuick

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I had to google that RZ500 I was thinking it was a calmed down version of the TD750 but I see I'm wrong. I also know why I never saw one (not imported to US) I would love to see that in person one day BUT my addiction requires that I not be within 10ft of cool Yamaha's :lol_hitti
 
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shopnut

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jbmatth – Thanks. Yeah, it’s great to get it on the road. I actually didn’t have much seat time prior to the teardown, so I’m now just learning the ergonomics and oddities of riding her. It’s all great!

Vehicle tinkering on tap for 2019 is some brake work on the Chevelle, rear wheel bearing work on the Corvette, and the baby sister to the RZ500, the RZ350, will see the light of day again. It needs new oil injector hoses and fuel system work. That will all keep me out of trouble, I would think.

Thanks for following along.

JCQuick – I even lusted after and finally bought an RZ350, and I didn’t know the 500 existed, so no worries there. It was years later when I stumbled upon them in an internet search for something on the 350. The RZ350s were allowed into the US only because Yamaha designed a special catalytic exhaust system for them. Even with it, they only were sold here for 2 years (’84, ’85).

I need to get you over to check out the bikes sometime. If Yamaha addiction is an issue, we will lock you in the upstairs office so you can maintain that 10ft buffer. Viewing is still pretty decent up there in the nose-bleed seats! LOL

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shopnut

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I’M FINALLY SELLING THOSE ELECTRONIC PARTS…

The longtime followers of this thread will remember when I purchased the pallet full of used cabinets back in 2014 and they ended up being completely filled with neatly organized (and free!!) electronic repair parts. Follow this link to the beginning of the story at REPLY #3064

3742-Crane-260.JPG 3743-Luxor-Cabinets-112.JPG

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When I first saw the spare parts, I knew they HAD to be worth some money to SOMEONE out there and decided to inventory what I had into an Excel spreadsheet. Parts were OEM HP (Agilent), Tektronix, and Fluke brands for old, but high dollar oscilloscopes, multimeters and other test equipment.

3745-Luxor-Cabinets-242.JPG

Fast forward to July of 2017. After settling into the new house and family life, and finding myself with small bits of time available again, I decided to finally figure out some outlet for them. I found an electronics forum that discusses the repair of old electronic test equipment and figured I would list the parts I had available there. It turns out that a Google search on any of the part numbers I have listed will turn up my forum thread on the first or second search results page. So anyone diligent about finding these old and somewhat rare parts are sure to stumble upon my offering.

I purchased the cabinets for $1400 and there was a $300 freight charge. The guy who sold the cabinets to me decided he didn’t want to mess with emptying out the cabinets (without my knowledge) because he assumed I might be able to do something with the old parts. Boy was he right!!

Here is a sample of some of the items in the bins:

3746-0005-Electronics-Inventory-85.jpg

I’ve been selling parts for nearly two years now. It’s a slow process that actually fits into my schedule nicely and I have mailed out about 25 orders so far (so maybe 1 a month, on the average). I have sold only 193 of the 12,935 parts in inventory (1.49%), but have already made $915 on the sales. (Having the inventory list in Excel makes it easy to determine those numbers!) So basically, the money for one of the two cabinet stacks has been recouped and I’m working on the second one. Perhaps if I keep doing it for another couple of years, it’s very likely the entire $1700 will be recouped.

Every now and then, someone seems interested in buying bigger lots of the parts, but I’m not quite ready to GIVE the stuff away yet. Someday, I may be ready, but for now, it’s sort of fun helping people fix their old equipment and making a few bucks along the way. The only real downside is over half of the orders are outside the USA, so I have to deal with customs forms and such, but at least that’s a good learning experience.

If anyone needs any NOS electronic test equipment repair parts, send me a PM!
 
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shortykorte

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Re: The ASYLUM - Turning a Crazy Vision into a Lakefront Gearhead Getaway: Year 6

2 yrs since you got married, boy time flies when we’re having fun.

Good to hear your efforts on the parts have started to pay off. I’ve been doing the same with some hardware and tools from my pawn shop days 21 yrs ago. I still make a few dollars when I set up at the swap meet.
Speaking of motorcycles and selling parts, I’m thinking we come to the Asylum after the cookout at JCs so we can pillage...Er, check out your wares and ride motos.


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shopnut

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Yeah times flies... its going on 3 years since the wedding. It has been fun though!!

I just responded in the FL GJ thread that I can't make it to JC's shindig. Really, really rotten luck with timing on my part since I haven't had very much going on lately and a GJ party would have been perfect. When it rains, it pours I guess. Man, I would love to see the FL GJ clan again. What a great group of guys to hang out with. Well, until the pillaging starts! LOL
 

cbacres

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attachment.php
[/QUOTE]

Mark, does the order picker work or do you just collect them like some other guys do?:lol_hitti

Nice view of shop, some day mine will cleaner like that!
 
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shopnut

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Craig,

I have a collection of exactly one, and I use that man-lift all the time! It’s a Cotterman model ML256. I tore my rolling scaffold down some years ago and haven’t turned back. Best $600 I spent in a long time. It may look rough, but it still works fine. Besides the obvious safety and ease of use benefits, I found it is really nice to be at the perfect height for the job (I had to pick a tier on the scaffold before, or take the time to adjust it). Plus I can just toss all my tools in there with me and up I go. It also gets used for an “elevator” to the front storage loft.

The step-daughter even thinks it’s fun to run up and down to hook up her aerial silks to the D-ring in the ceiling.

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Here she is, practicing some moves this past weekend:

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shortykorte

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All great shops have a manlift/order picker, running or not.
CB, Cleaner than Shopnut’s..after you paint the SL for me. [emoji12][emoji12][emoji12]

Sorry you can’t make it. Just leave the key under the mat. We promise we’ll leave like we found it.

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shopnut

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HOTFR8 – It IS interesting to watch. And a bit nerve-racking knowing a loved one is in a position to potentially get hurt! When I was dreaming up the shop and the multi-use aspect of it, I never would have guessed one of those uses would be aerial silks! I’m glad the old Asylum could accommodate, however!

shortykorte
– The thought of the FL GJ crew in here unsupervised sends a shiver down my spine and I’m sure I’ll have a few nightmares in the upcoming nights!! LOL

JCQuick
– Still ***** about the bad timing. I wonder how long I would be in the doghouse if I missed my first step-grandson’s baptism. Hmmmm. :headscrat
 
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shopnut

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GETTING THE SHOP ORGANIZED (Part 57 of ?)…

LABELS FOR THE CABINET DRAWERS.

I’ve been utilizing post-it pads for drawer labels for way too long and it was time to decide on my final labeling method. My drawer pulls are aluminum extrusions that are designed to have labels slipped in from the end. This would function just fine, but it doesn’t look quite finished to me… maybe it’s the ribs, I don’t know.

3748-Luxor-Cabinets-957.jpg 3749-Luxor-Cabinets-958.jpg

I decided the best route to go was slip in a full length strip of steel to finish it off and then apply my labels to thin magnetic sheets. A side benefit of going with magnetic labels is the ability to move them from these drawer cabinets to any of the door cabinets if the contents are moved in the future… complete flexibility!!

First of all, I needed 24 strips of steel at 5/8” wide. Luckily, pallet strapping is cheap and available in 5/8” width, among others. I got a 300’ roll for $30. Width is extremely consistent and fit in my drawer pulls perfectly.

3750-Luxor-Cabinets-956.jpg

Next question, what color should the steel strips be? To answer that, it was easy enough to try both and just take a look. My wife and I both agreed the black was hands down the finishing touch. Black is also a good choice because the strap already comes in black. (BTW, these samples were 1/2” wide strap material I had on hand before the proper 5/8” strap was delivered)

3751-Luxor-Cabinets-886.jpg 3752-Luxor-Cabinets-889.jpg

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So black it was and I started cutting 24 of pieces from the roll. Here is one full cabinet with the steel strips inserted.

3754-Luxor-Cabinets-948.jpg
 
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shopnut

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GETTING THE SHOP ORGANIZED (Part 58 of ?)…

LABELS FOR THE CABINET DRAWERS (continued).

Next, it was time to give the label maker a little workout. I had some silver label tape that seemed to fit the color scheme nicely.

3755-Luxor-Cabinets-952.jpg

I made some sample labels in different fonts.

3756-Luxor-Cabinets-951.jpg

I settled on the biggest font my trusty label maker could produce, namely because that bottom drawer is waaaaaay down there for these aging eyes.

3757-Luxor-Cabinets-954.jpg

Here is one of the cabinets with all labels in place.

3758-Luxor-Cabinets-960.jpg

The silver labels are affixed to magnetic strips.

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SAE fastener drawers.

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Drawers of small plastic, aluminum, and steel brackets and stock for various projects.

3761-Luxor-Cabinets-964.jpg
 
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cbacres

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Mark, great idea on the strapping, I'll have to look at my handles to see what size, but I think there bigger. I have a tool or two of the magnetic strips, I probably should make up labels to use for the time being as my contents location havnt settled down.

I like the black, it pops nicely.

Nice of you to get it all labeled up, it'll make it easier for those drawer hoes.:lol_hitti
 
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JCQuick

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Oh yeah the old sticker / label on magnet trick :lol_hitti Who would have thought of that ? says this old parts man. Its funny I found these when I was in the petroleum biz and turned my current employer on to them.
 

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taumac

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The thought of the FL GJ crew in here unsupervised sends a shiver down my spine and I’m sure I’ll have a few nightmares in the upcoming nights!! LOL


Hmmmmm, I have no idea why your so scared. As Prez I’ll make sure nothing is out of place when you return.... for the most part. BTW just make sure first aid kit is stocked up. It would be a shame for Shorty to drop blood all over that beautiful floor.
 

shortykorte

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Re: The ASYLUM - Turning a Crazy Vision into a Lakefront Gearhead Getaway: Year 6

True. Having teenagers can keep you busy. Would be nice to get a post. I bet if we stormed the Asylum he’d post. Lol.


Shorty Korte
Always remember quality in QST

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taumac

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Re: The ASYLUM - Turning a Crazy Vision into a Lakefront Gearhead Getaway: Year 6

Let’s do it. Gather up the crew and invade the Asylum. [emoji12]
 

JCQuick

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Re: The ASYLUM - Turning a Crazy Vision into a Lakefront Gearhead Getaway: Year 6

Let’s do it. Gather up the crew and invade the Asylum. [emoji12]

I would be down for that :beer: he stated his new city home was up my way i've been keeping a look out for some of his cool bikes that Yamaha should be up and going by now too.
 

taumac

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Re: The ASYLUM - Turning a Crazy Vision into a Lakefront Gearhead Getaway: Year 6

I would be down for that :beer: he stated his new city home was up my way i've been keeping a look out for some of his cool bikes that Yamaha should be up and going by now too.



It will be a surprise visit. You know “key under mat... let ourselves in....” type idea. [emoji38] Could you imagine look on his face when he show up to shop and find us in his shop doing a GJFC inspection. [emoji1787]
 

shortykorte

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Re: The ASYLUM - Turning a Crazy Vision into a Lakefront Gearhead Getaway: Year 6

Or we just rearrange everything and leave our bottle caps in the drawers. He’d never know it was us.


Shorty Korte
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JCQuick

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Ok first part of plan is find it. i'mm just saying . We know it is on a sail boat friendly lake with lots of trees. should not be hard to find in Florida
 

shortykorte

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Ok first part of plan is find it. i'mm just saying . We know it is on a sail boat friendly lake with lots of trees. should not be hard to find in Florida



First part of plan-completed


Shorty Korte
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shopnut

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cbarces - Thanks. (sorry for the REALLY slow response LOL) The labels have been working out really well and I’m glad I spent the time doing it. Funny story regrading that… I had to by 300 ft of that strapping because it was a special width (5/8”) and I used maybe 40 or 50 ft of it, so I have plenty left. Luckily it was cheap (~$25). Then, about 3 months later, the supplier sent me another 300 foot roll. Now I have about 550 ft of it with no real use for it. It figures this happened with something I didn’t need!!

JCQuick/taumac/shorty – You guys are too funny! I ought to plan a little Asylum get-together sometime so y’all can catch me up on what’s been happening on the GJ forum. I barely have time to update the bike project progress on those forums. Yes, shorty is right… teenagers can require a lot of time. Ours is right at that age where she wants to do EVERYTHING, but doesn’t drive yet, so chauffeur duties are quite high lately. She has her learner’s permit now, so more free time may be on the horizon. BUT, it may end up being free time to worry about her out and about by herself. We shall see.

I had such good luck with the Yamaha RZ500 project, I figured I would transition right into working on her baby sister, the RZ350. But sitting for 8 years while the Asylum was getting outfitted has taken its toll on the old girl. The engine needed to be pulled and major work done and that’s where I’m at right now (see below). I have I lot of vacation in December so I’m hoping it will be back together soon, maybe even before the new year.

Oh, and JC, I’m driving around the Apopka area quite often, but usually in my black Avalanche or on my black cherry FJR1300. The cool bikes don’t venture too far from the Asylum.

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taumac

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Re: The ASYLUM - Turning a Crazy Vision into a Lakefront Gearhead Getaway: Year 6

Yes, you definitely should. We only been waiting how long. LOL!!! You really shouldn’t worry too much. We all went to JCs place and at the end of the day he still had most of his hair left. LOL
 

shortykorte

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Re: The ASYLUM - Turning a Crazy Vision into a Lakefront Gearhead Getaway: Year 6

Imposter! Imposter! Verification question, What color did you use for accent color in Asylum?

Mark Just ignore our post. Lol.

Whispering: Ok guys, December might be out since you-know-who might be in the place on a regular basis.


Shorty Korte
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shortykorte

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Re: The ASYLUM - Turning a Crazy Vision into a Lakefront Gearhead Getaway: Year 6

Imposter! Imposter! Verification question, What color did you use for accent color in Asylum?

Oh hey Mark. Just ignore our post.

Whispering: Ok guys, December might be out since you-know-who might be in the place on a regular basis.


Shorty Korte
Always remember quality in QST

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shortykorte

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Re: The ASYLUM - Turning a Crazy Vision into a Lakefront Gearhead Getaway: Year 6

Adjustments.jpg


Shorty Korte
Always remember quality in QST

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shopnut

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taumac - I still wish I could have made it to JC’s shindig. Instead I sat in the car that day for 6 hours driving to Ft Myers for a 1 hour event. Life just isn’t fair sometimes!!

shortykorte - Merry Christmas! Happy New Year! Happy Valentines Day! Happy Easter! Annnnnnnd Happy Memorial Day!! There, I think I’m caught up! Geez, has it been that long since I posted?!? Life is going way too fast.
 
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shopnut

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cbacres - Yeah, I haven’t been posting anything lately, but I have a ton to catch you guys up on. I hope you and yours are doing great down in F.M. Thanks for stopping in.

Ody - Hey, thanks a lot!! I need to blow the dust off of this thread and get some updates posted. The Asylum is still very dear to me. I’ve been trying to catch up on a bunch of stuff while this COVID-19 thing is going on and have been accomplishing a lot. I hope you and yours are doing well on the other end of the country.
 
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shopnut

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NEW STAIRWAY AND LOADING DOCK…

I have been trying to take advantage of the weird situation all of us are in due to this COVID-19 pandemic by catching up on a lot of projects that have been on my list for years. With the ASYLUM being sort of a germ-free safe haven, it has been easy to zip out there as much as I want without any worry of catching something. I guess I now have another reason as to why I called this place “The ASYLUM”. I have gotten a TON of stuff done to report on.

Fifteen years has passed since I built the original stairway leading down to lake and it was showing its wear. This is what I started with. It was still usable, but I wanted to be a bit proactive about it before it turned into an emergency (or another trip to the emergency room!)

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I do use this stairway as my loading dock, so having some nice sturdy boards on the top step again will be reassuring.

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Tread material is 2x6 pressure treated lumber. Risers are 5/4 x 6”. No cutting needed!

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In an effort to prevent the stringers from shifting around during all this, I left one tread board on each step.

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And then added the new board next to each one. It worked out well because the old board provided the great place to pry on, forcing the new board back into the corner tightly of all three stringers.

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All treads done and the beginning of the risers going on.

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My stairway is safe for another 15 years hopefully.

3769-Exterior-Stairs-Rebuild-11.jpg
 
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