Welding Tank, Tail Repair and Mock Up

Tank Chop

 Tank from a Suzuki 850 does not fit over the Virago frame

Marked out an area to cut. Used a small Dremel cutting wheel to remove the offending metal

For the other side I decided it may save on time by drilling holes first

 Bend back the metal.

Inside is what looks like a small mouse house - the mice are not home

 Once both pieces were removed, the tank fits but only just - it will need more clearance before I can weld the holes closed.

 And with the tail piece, just to get an idea of how it might look.

Suzuki - Top End Rebuild - The End

Suzuki - Top End Rebuild - Day Three

 All clean.

 Tapping out three stripped bolts on the cam bearing cover

Suzuki - Top End Rebuild - Day Two

 Cleaned valves - not perfect but looking much better

Valve grinding the old fashioned way

 Valve grinding the new way. A thick piece of rubber and a slow setting on the drill works much better

 All springs measured and within the allowable tolerances

  Shims measured in preparation for gaping after reassembly

 All valve thicknesses measured and within the allowable tolerances

All valve stem thicknesses measured and within the allowable tolerances - unfortunately, I don't have the ability to check valve/cam shaft run out, valve guide wear or several of the other valve angles.