Honda XL250 paint prep…

The Honda XL250 paint prep begins...

The Honda XL250 paint prep begins…

The Honda XL250 paint was going to consist of spraying quite compared to most vintage bike.  While the body filler was drying, we got to work on the rest of the bike…

Honda XL250 paint for plastics…

The hardest part of prepping for the Honda XL250 paint involved stripping the old factory paint from the plastic fenders and headlight bucket.  Using the wrong type of stripper can melt and distort the base plastic, so we ended up using lacquer thinner.  It was a tedious process, especially considering how rapidly the thinners evaporate.  Eventually, we decided to soak the parts with thinner, and then cover the entire fender with aluminum foil.  This kept the solvent on the part long enough to bubble the old paint.  In the photo above you can see the progress of the paint stripping.

The Honda XL250 frame gets scrubbed...

The Honda XL250 frame gets scrubbed…

We decided to paint the frame ourselves, instead of opting for the typical powdercoating.  The painting would require getting every inch clean, since it would not be sand-blasted prior to painting.  While the solvent did its thing on the fenders and headlight bucket, we rolled the frame outside to give it a good scrubbing.  This Honda XL250 was covered in 45 years of old grease, grime and mud.  After spraying a ton of engine degreaser onto the frame, we used a hose to get the majority of the crap off.  We followed up by hitting it with some soap and water, and good stiff brush.  The frame began to reveal itself from beneath the grime.  The problem was; rust.  It quickly became apparent that the frame would need to be treated before painting.  Years of sitting had allowed moisture to seep into certain areas creating some trouble spots.

Engine grime…

Kami's job was to clean the Honda XL250 engine...

Kami’s job was to clean the Honda XL250 engine…

Next up, the engine.  You can see from the photo above, this thing hadn’t been cleaned in….well, ever!  So we got Kami on engine scrubbing duty, and had her work her magic.  Fortunately she has shown a knack for getting every nook and cranny clean on these old engines, so we are hopeful the end result will match the rest of the bike.

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