6-12-11 6 hrs. Got the bike running and took it for a ride!!! Oiled and installed the air filters, installed points and plugs, adjusted the timing, troubleshot the the wiring (coil not plugged in all the way). wired in the handlebar switches, reinstalled the headlight, installed front fender, filled engine with oil, adjusted the chain, torqued bolts through out. Cleaned gas tank varnish with a gallon of carb cleaner I bought from NAPA, rebuilt the petcock including new seals, installed new gas lines, mixed three gallons of gas, installed new gas cap and keys.

Bike Started 3rd kick!! and ran great. Now time for fine tuning carbs and final touches after which comes the nice paint job

6-11 5hrs installed reeds, manifold and boost bottle using new parts I bought off of USA 2stroke forum. I decided not to use the boysen reeds due to the design. Install carbs and new fuel lines, clean filters.

6-5-11 2hrs - Installed the tail light. I assembled the rear fender, taillight assembly and lens then installed on the bike. I also installed the seat and tank just to see what it looked like. Really starting to look like a bike, Hopefully in about two weeks it will be running!

6-5-11 3hrs Worked on the seat. The foam was dry rotted so I had it repaired locally by a person who does boat upholstery. That piece came out good; they steamed the foam, removed the dry rot, and added a small thin soft layer of foam($20). I bought a new seat cover from HVC. Went installing I used small self tapping screws and fasteners to hold the cover in place because the small original clamps were weak or rusty. Over all the seat looked really good until I put on the safety strap. The strap caused the seat foam to compress and therefore made the seat look wrinkly. To correct the issue I will probably need to purchase new seat foam, seat pan and another cover (about $400). Because of the cost I am going to wait until I can find another seat. While not perfect, the seat is a big improvement over what I had...

6-11 4hrs. Completed the front and rear brake systems. Installed new SS brake lines and pads along with the rebuilt calipers and master cylinders. What worked really well was a vacuum brake system bleeder kit I bought from harbor freight for $45. I t made bleeding the brake systems a snap. The new SS brake lines are smaller in diameter. I had to find new rubber keepers (mounting clamps) at the hardware store. Installed the ground on the coil, left and right handlebar controls and new (original style hand grips). Also installed the rear view mirrors

6-1-11 4hrs Started on carbs. disasembled carbs and reed cages, and cleaned. All looked great. Hit a snag wen I went to install new boisen reeds. For some reason the new reeds are much smaller than the originals, but they do fit with the provied adaptor. Will email boisen to ask for input.

6-1-11 8hrs Primed and painted pipes. Installed on the bike. all went well except for the rear mounts. Some frame modifications will need to be done to accepted the rear brackets. Fixed the clutch issue, basically it was the incorrect installation of the clutch mechanism on the left hand side of the bike (that's what happens when you get a bike in pieces); all is well and the clutch has much adjustment left in in. What was a big help was a rd400f parts manual I bought off eBay from a company in Australia ($30). The graphics and the related part descriptions really aided in correctly assembling the clutch mechanism.
Also fixed the kick starter by taking apart and reinstalling.
I continued assembling the rear brake system. After much conversation on the USA 2 stroke forum, I received good guidance to buy a brake vacuum bleeder kit, which I did from harbor freight ($40). I will try it this weekend.

5-21 8hrs Painted pipes, 3 coats. Started soaking the gas tank in acid (used bathroom cleaner "the works" from Walmart; recommended by the guys on USA 2 stroke forum). The inside of the tank is a mess, full of rust and varnish from old dried out gas, looks about 20 years old. Assembled more wiring and installed headlight and front blinkers. Went to install new points and condensers but had wrong parts. Torqued the head and all engine mounts. Cleaned chain and installed. Installed the clutch mechanism, cable and hand control (didn't work, need to open up clutch basket to see what is going on). Installed the kick starter, it jammed; will check when I look at the clutch. Installed new rear stainless steel brake line and the rebuilt master cylinder. Still working on the front master cylinder; having issues getting it to work. Rebuilding front hand light switch.

5-15 Finished calipers; 4 hrs. cleaned and prepared for painting, painted w coats of caliper paint. Installed new seals and stanless steel capiler pistons. on to the master cylinders and new brake lines

5-8-11 4hrs Seized Brake calipers and master cylinders. These things are a mess. Steps I took to unseize calipers
1 -soaked in a pail of wd 40 for a week
2- put the caliper under pressure in a vice to "crack them free"
3 - connected the caliper to the front master cylinder and "pumped" the calipers out
I am now waiting on the new caliper pistons and the new SS brake lines to come in. I have all the rebuild kits for the front and rear master cylinders and the front and rear calipers

4/25 Reinstalled the wiring harness from the taillight to the headlight. Found out I am missing a many parts for the headlight assembly. 3Hrs

Looked at the calipers, they seem quite rusted and seized, much like an old boat motor that had been sitting in salt water.

Ugh back to the Internet to locate used parts...

4/24 Painted and reassembled the tachometer, speedometer and indicator lights. Installed all new rubber mounts, chrome hardware and decals. Also painted and reassembled the left and right handlebar controls and installed decals. 4hrs

4-23  She's a rolling!
cleaned and retaped wiring harness, painted dash parts, installed new fuse box, installed motor mounts,  polished chain tensioners, polished and installed handle bars, installed shim on swing arm, installed rear rim with all spacers, installed new grommets on footpegs, installed foot pegs, installed kickstand and spring. 6hrs

4-22 Installed front tire. Looking more like a bike every step! Next I am going to spent some time disassembling, cleaning and painting the gauges, headlamp, and handlebar controls...

4-22 Installed the triple tree, front forks and headlight bracket on the bike. 2hrs

4-22 Polishing front forks; pic is before and after. Wire wheeled the corrosion off the surface then ran on the course buffer with black and red compounds. Finished with white compound on the fine buffing wheel. 3hrs

Finally it is starting to look like a RD! 1 hr

Engine together. 3 hrs

One Jug On

Started to rebuild engine. Bored 1 size over, new Wiseco piston, rings, wrist pins, roller bearings

Started to reassemble Frame. 3 hrs. The common issue with the frame is that the after market parts dont fit and or are not built quite the same, which makes things time consuming

back into it

benn off a few weeks... bad weather work, etc.  looking forward to the weekend

Frame Painting

Sanded frame and swing arm with 300 and 500 grit sandpaper. Painted base coat with etching primer and 2 coats of black primer. Applied 2 finish coats of black acryilic enamel and 2 coats of clear. 7 coats in total. 6 hrs

Frame Preparation

Power striped the rust off the frame and swing arm with a wire brush and 3/8 drill and a dremel tool; then power washed the frame. Removed old swing arm bushings. 2hrs

RIMS - Finished Painting

Painted both rims with black sandable primer, two coast of black enamel and 2 coats of clear. Once all was dry I removed the tape and stripped the paint off the cast spoke area of the rim. 4hrs. Rims came out awesome. Installed new bearings and seals

Rims - painting

prepared rims with duplicolor cleaner, taped and painted with duplicolor etching primer (2 coats) 4hrs

Rims -prepping and polishing

Stripped paint from rims with wire wheel and drill. Polished aluminum surfaces by wet sanding with 100, 220, 360 grit; then buffed with black, red and white polishing compound and various buffing pads. 5hrs

Painting and polishing

Researched painting frame and wheels and polishing aluminum parts. Quoted price to have these items done was over $1000. I will now do myself for $200 in materials. See Useful links tab for painting rims using duplicolor paints (youtube) and another link for polishing aluminum (you tube video)
4hrs

Frame

Spent 3 hrs grinding and prep frame

Found Carbs and Pipes

Found a used set of DG pipes and 32MM flatside mikuni's on line at the usa2stroke.com forum.  $500, some guy Russ from CA. Nice guy, he use to race back in the day and is also currently starting a daytona project of his own. CA really seems to have more enthusiest for the 2 strokes