Suzuki GT750 J/K - Side cover restoration

This page documents the repainting of two J/K side covers in the typical condition they
usually are at the point where they become subject to reconditioning.

Click here to view my repainting of another pair of covers, a success story

Phase 1 - Preparing the covers for the repaint process

Removal of the aluminium mesh requires removal of the fastening washers which were fixated by melting the plastic tab. This melted surface can be cut using a plier like the one shown
above.
This animation shows usage of the plier for removing the melted plastic that hold the washers. Cut around the edges to leave the center plastic tab intact. This means it can again be melted down to lock another washer in place during reassembly. This works once, after which the tab will become too short to make it useable.
The holes typically crack due to mounting washers having been to tightly mounted

Typical flaws on sun-burnt side covers and vibration wear from 'water cooled' emblems.

Emblems are typically not pretty, this one is beyond rescue.
New ones cost between 60-150 dollars/pair depending on how lucky you are.

Seasoned CCI decal

Typical dealer quote for a new one:
68171-26000 - Emblem, CCI (Qty. 1) - $2.00

The washers that holds the 'watercooled' emblems are typically difficult to remove.

09148-04007 Nut, Frame Cover Emblem Qty. 1 $0.80

Four (4) are required.

Unfortunately the emblem locking washers fight hard to stay in place so they are typically destroyed by removal.

Here are the covers ready for the next process - wet sanding down the blue candy layer.

Phase 2 - Wet sanding down the blue candy (April 15, 2001)

Bathtub a decent place for this work.
400 grade paper.
Doing a horseshoe shaped headlamp bucket at the same time...
Ready for primer and silver coat,
not neccessary to sand off more than this.

Phase 3 - Silver coat (April 16, 2001)

Silver coat applied on top of primer.

Phase 4 - Candy layer

Color sample...looks good despite the age.

Can label
Lid..

Repainted covers

Phase 5 - Clearcoat

I will skip this stage due to lack of a suitable clearcoat paint for my spray gun.
Rattle can clear is too risky.

Phase 6 - Reassembly

The 'grille' components are sandblasted and repainted. Also each of the little washers that hold it in place...

Reinstall the restored grille

Install the washers, heat up the soldering iron....

The plastic is melted to lock the washers in place. Done !!

Done. Complete with "Water Cooled" emblems installed.

Removal of the aluminium mesh requires removal of the fastening washers which were fixated by melting the plastic tab. This melted surface can be cut using a plier like the one shown above.	This animation shows usage of the plier for removing the melted plastic that hold the washers. Cut around the edges to leave the center plastic tab intact. This means it can again be melted down to lock another washer in place during reassembly. This works once, after which the tab will become too short to make it useable.	The holes typically crack due to mounting washers having been to tightly mounted Typical flaws on sun-burnt side covers and vibration wear from 'water cooled' emblems.
Emblems are typically not pretty, this one is beyond rescue. New ones cost between 60-150 dollars/pair depending on how lucky you are.
Seasoned CCI decal Typical dealer quote for a new one: 68171-26000 - Emblem, CCI (Qty. 1) - $2.00	The washers that holds the 'watercooled' emblems are typically difficult to remove. 09148-04007 Nut, Frame Cover Emblem Qty. 1 $0.80 Four (4) are required.	Unfortunately the emblem locking washers fight hard to stay in place so they are typically destroyed by removal.
	Here are the covers ready for the next process - wet sanding down the blue candy layer.