Featured Tiger 90 Rebuild

I only need one rattle can of paint to touch up the worst spots, so it sounds like my best bet is to go to a motor shop with the mudguard and pick a can of the closest colour.

 

I checked out RS motorbike paints, but for a 250ml can it cost £36 with delivery. :-(

 

Oops, looks like I said “Arctic” when I meant “Alaskan”. Well they’re both cold places that start with the same letter.

 

Put the rear mudguard on, with the nuts and bolts hand tight to allow adjustment later. The touch up to the original paint shows up, but it’s not too bad and it’s in keeping with the “preservation” look that I’m going for, not a rebuild to look like it’s from a showroom.

 

Cleaning the inside of the oil tank.

 

Well it took a lot longer than expected to clean the inside of the oil tank as there was a thick layer of carbon sludge at the bottom. I got it out by sealing the holes, putting some petrol in with some nuts and screws then shaking vigorously. Rinse and repeat six times before it was clean. If it hadn’t worked I may have used a jet washer. Next step is prepare to paint the back of the tank. The front will be polished up with T cut.

 

Left hand side panel: brazed a bracket back on and a split near the top at the back. Bit messy.

 

The rear end of the chain guard. At some point the chain has rubbed through and the remaining metal is paper thin. It is too delicate to fill with braze, but because it is non-structural I intend to use car body filler and a piece of metal to strengthen it. Body filler is not really the way I want to go, but it’s easier than cutting the bad piece out and welding a new section in (which would still need filler at the join). Maybe a second hand one could be sourced, or even a new one but I am trying to keep the cost down.

 

@darkman - that’s the right answer!
I remember my mates filling rust holes in their cars with lead solder in the days before epoxy fillers. I was thinking of going down that route, but your suggestion is better.

 

That’s a really good website. I won’t be at Stafford but hope it goes well for all concerned.

 

Coming together nicely, and started putting the loom in. The upside down gremlins strike again.

 

The lighting switch in the side panel should be marked OFF, LOW and HIGH. This one is marked IGN, OFF, EMG, but it has the correct pins and connections except one.