Bodywork and Paint

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Body work time. I sanded the replacement tank down and found lots of minor dings, a few scrapes, and a few larger dents.

Most of this will dress out with featherfill, but not all.

This is one of the larger dents, just above the badge area. There is another dent towards the rear of the tank, where that blue paint still is.

This one is deep, but small. Probably had something dropped on it.

And a few deeper dents at the very front of the tank.

Next I started to tackle those pretty blue side panels. They seem to have lost their crisp edges, so I suspect there are a few layers of paint that I will need to sand through.

However, I never suspected this. By the time I was done, I found 9 paint layers. No wonder they had lost definition.

This shows the various layers. Now, I could have kept sanding everything back to the base black panel, but we looked at this and decided to stop here. This patchwork is something you really can't duplicate.

All the sanded body parts were sprayed with sealer. We had a second front fender, but since both had minor issues, we decided to see which would work out better. We had also found a second rear fender so that we didn't have to paint the chrome one.

The top sides in the sealer. Time for bodywork.

The areas where we did not want the featherfill were taped off.

Then we sprayed featherfill on all parts, not just the tank.

The front and rear fenders in featherfill.

Time to sand everything smooth, starting with the rear fender.

The tape was removed from the tank before sanding. It won't take much sanding to get this smooth.

The first fender sanded out so well that we decided to store the second fender as is.

It's a good thing I prefer sanding by hand. Every piece is nothing but curves.

The rear fender ready for color.

The front fender ready for color.

So is the tank. The dents and dings are all gone.

The side dents are gone as well. Featherfill is amazing, but there was a few touches of putty in a couple of the dents.

Time for the seal coat under the color.

The Ranchero was covered up during this process.

Time for color. We will be using a 2 part system of base coat and clear coat.

Yes, the bike was blue when we got it. But Kurt likes blue motorcycles, so we went back with something similar but a few shades darker.

The original side panels were just sprayed with clear to preserve the mottled colors sanding had revealed.

This is a beautiful blue, now with clear.

The front fender in color and clear.

And the tank. Notice the reflection of the photographer in the finish.

The other side of the tank. No dents.

And those mottled side panels. Kurt named the bike Jawbreaker.

Time to reassemble the bike with the freshly painted parts.

The painted parts had to be stored for a short while as we finished up with the Rebel.

These are an original set of side panels. Notice the crisper edges. The badges will be removed and I'll lightly sand these to give a smooth finish. Then we can paint them, but that will come later. Time to put this beauty back together.


Original Condition
Original Condition