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Custom Motorcycles » 1980 Ironhead Sportster Chopper
Re-Painting the Tanks and Fenders

Re-Painting the Tanks and Fenders

Posted by Justin on 5/5/2005
When I bought this bike it had a teal metallic paint job with silver flames. The paint was chipped, the gas tanks were visibly dented, the oil tank was very rough around the edges, and there was rust in several places. Once I got to ride around a few times and make sure it was worth restoring, I tore off the painted parts and started stripping them down to the bare metal.

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Progress Update 5/3/05

Progress Update 5/3/05

At this point all of the paint and old filler is gone. I've ground down the ugly weld seams on the oil tank and am currently in the process of adding bondo filler to the tanks and rear fender. I'm also working on taking apart and repairing the brake calipers and rear master cylinder, and polishing some of the chrome and aluminum parts.
(7 images)
Repairing the gas tank seam

Repairing the gas tank seam

I got a little too ambitious with the angle grinder trying to clean up the line along its weld seam, and ground all the way through it. After hours of welding, brazing, and grinding the small pinholes would not go away so I decided to fill them with bondo on the outside and use a POR-15 motorcycle tank sealer kit on both tanks, which will also remove and prevent rust. The kit is around $33 on por15.com.
(6 images, 1 comment)
Setup and Paint Stripping

Setup and Paint Stripping

(7 images)
Shooting the Primer

Shooting the Primer

I'm using a black, 2-part high fill polyester primer. At first I was shooting with an older DeVilbiss JGA-502 siphon fed sprayer, but then I switched to a new inexpensive HVLP gun from harbor freight. The paint I'll be using is a gloss black basecoat/clearcoat combination consisting of Sherwin Automotive Ultra 7000 and Western brand clearcoat.
(5 images)



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