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78' KL250 06 Apr 2023 18:30 #882580

  • Kelly E
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I've been working on a 15k mile 78' KL 250 I picked up for the boy to learn on. My biggest hurdle was swingarm bushings and the rotten exhaust. I've already made swingarm bushings from Delrin and now I'm almost done building an exhaust system. I used the stock headpipe, parts of the number 2 and 3 headpipes from the old 82' CB 900F exhaust and the old right side muffler from the 84' Honda Sabre 700. I still have to make a muffler mounting bracket for it and fix/reinforce the broken off coil mount.Then I can get on with pulling the motor and sandblast the frame, swingarm and related parts. Rick Brett even made me a new set of VIN stickers for it.
The Rust Bros. Garage Collection
1974 Honda CB550 K0
1975 Honda CB400F Super Sport
1977 Kawasaki KZ1000 LTD
1980 Suzuki GS1100E
1981 Suzuki GS 1100E
1982 Honda CB900F Super Sport
1983 Honda CB1100F
1984 Honda Sabre 700
1984 Honda Interceptor 1000
1994 Kawasaki ZG 1000 Concours
And more

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Last edit: by Kelly E.

78' KL250 06 Apr 2023 23:12 #882586

  • Wookie58
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Great work as always Kelly 
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78' KL250 07 Apr 2023 19:11 #882648

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I got the muffler mount made today.
The Rust Bros. Garage Collection
1974 Honda CB550 K0
1975 Honda CB400F Super Sport
1977 Kawasaki KZ1000 LTD
1980 Suzuki GS1100E
1981 Suzuki GS 1100E
1982 Honda CB900F Super Sport
1983 Honda CB1100F
1984 Honda Sabre 700
1984 Honda Interceptor 1000
1994 Kawasaki ZG 1000 Concours
And more

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78' KL250 05 May 2023 14:09 #884289

  • Kelly E
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We've got the frame sandblasted and ready for paint. Yesterday I reinforced the lower rock guard mount and today I made the rest of the rock guard to cover the bottom of the frame. I have to put the motor in one more time to make sure the drain plug access hole is in the right spot. I'm now waiting for a good day to get the painting done.
The Rust Bros. Garage Collection
1974 Honda CB550 K0
1975 Honda CB400F Super Sport
1977 Kawasaki KZ1000 LTD
1980 Suzuki GS1100E
1981 Suzuki GS 1100E
1982 Honda CB900F Super Sport
1983 Honda CB1100F
1984 Honda Sabre 700
1984 Honda Interceptor 1000
1994 Kawasaki ZG 1000 Concours
And more

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78' KL250 19 May 2023 15:11 #884939

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Today we got the frame painted. We painted it in the new shed on the back of the shop out of the direct sunlight. I was able to see way better and the paint wasn't turning to dust before it hits a nearby frame tube. Once done we carried it back in and hung it up. Tomorrow I'll get it raised up high to cure. In a couple of weeks I'll pull it down to mask off the areas that will be sprayed with bedliner.
The Rust Bros. Garage Collection
1974 Honda CB550 K0
1975 Honda CB400F Super Sport
1977 Kawasaki KZ1000 LTD
1980 Suzuki GS1100E
1981 Suzuki GS 1100E
1982 Honda CB900F Super Sport
1983 Honda CB1100F
1984 Honda Sabre 700
1984 Honda Interceptor 1000
1994 Kawasaki ZG 1000 Concours
And more

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78' KL250 01 Aug 2023 15:59 #887785

  • Kelly E
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We've got the motor in the frame and the suspension installed. I have to put on the new VIN sticker from Rick Brett and I was wondering if anyone has any tips for installing it?
The Rust Bros. Garage Collection
1974 Honda CB550 K0
1975 Honda CB400F Super Sport
1977 Kawasaki KZ1000 LTD
1980 Suzuki GS1100E
1981 Suzuki GS 1100E
1982 Honda CB900F Super Sport
1983 Honda CB1100F
1984 Honda Sabre 700
1984 Honda Interceptor 1000
1994 Kawasaki ZG 1000 Concours
And more

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Last edit: by Kelly E.
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