Honda XL250 Rebuild…

Honda XL250 Rebuild. It all starts with the tank...

Honda XL250 Rebuild. It all starts with the tank…

The Honda XL250 rebuild has been stalled for far too long.  It’s been a whopping 4 years since we got this old gal, but we have finally begun to make some serious progress….

The Honda XL250 rebuild takes shape…

Honda XL250 rebuild tank with body filler and Corroseal...

Honda XL250 rebuild tank with body filler and Corroseal…

It all began with the tank.  Namely, getting some of the dents out of it before stripping and prepping for paint. We have never had any luck with the pop-a-dent contraptions, but fortunately we gave it another try, and the damn thing worked!  A couple small dents were repaired, and a couple more were brought to a reasonable state for body filler.  Once the tank was stripped, it was coated with a dual-purpose product called Corroseal to prevent flash-rusting.  This metal rust inhibitor and metal primer is priceless, allowing you to take your time getting to the body work.  The Corroseal goes on milky white, and dries to a black coating (shown in the photo above).

Body work is certainly not our favorite task, especially with the inferior Bondo brand filler.  But after switching to Evercoat Rage filler, the process went much smoother (pun intended!).  It took several applications of filler, followed by sanding, and then more filler to get it just right.  Sadly, after the first round of primer, it became evident that we needed a little more filler.  The primer really brings out every detail in the body work.  We stumbled across a product called Mirka Dry Guide Coat that helps eliminate missed or problem areas.  The guide coat is a black powder that goes on with the included applicator, and then gets sanded.  Any high or low spots become instantly apparent.  This will be used for all future projects since it really helps avoid wasted time, primer and patience.

 

The amount of '70's dirt removed has been staggering...

The amount of ’70’s dirt removed has been staggering…

Elbow grease and degreaser…

While we waited for body filler and primer to dry, the next step was to get the rest of the bike broken down and cleaned.  This turned out to be no easy task.  Apparently ’70’s mud and grime likes to stay right where it is – and it took several hard scrubs to get it to let loose.  Suds and water, engine degreaser, and a ton of elbow grease got us to the finish line.

The Honda XL250 rear wheel and cush drive gets clean...

The Honda XL250 rear wheel and cush drive gets clean…

There are few things as satisfying as seeing cleaning progress.  Attacking the wheels proved that deep under all that grime is a great looking part.  Little by little, progress is made, and the effort on this little Honda XL250 is starting to show….

Stay tuned for updates.

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