Observations on a Restoration

During the course of this project, I definitely came to points in the build where I'd regretted the timing or decision from an earlier point, or after making the same mistake for the fifth time, wished for a more efficient approach.  For example, I purchased several parts very early on which should have been 'no-brainers', but found out too late to return them that they would not work or were not right or where my approach had since changed (fork springs and m/c rebuild kit for two).  All in all, however, the timing and cost were not too far off my estimates.  The overall effort required to complete this project was maybe a little more than I'd hoped for.  But even after much detailed planning, nothing is ever exactly what you think it will be.

Your project may be more or less involved, or may require more sophisticated design and fabrication than mine did.  This 850T project called for significant disassembly and cleaning, polishing or de-rusting and painting of almost every component.  Minor brackets were fabricated and creative solutions required for a host of aesthetic and functional elements.  These are some thoughts I've had on the project as it unfolded, where I frequently uttered the words "next time" before I even knew what I was saying (then quickly glanced around to check that my wife was not over-hearing me).  I'm thinking there may be, however....!

One more thing - do all cleaning and repair and refurbishment and fabrication work BEFORE paint.  You will be tempted to flesh out your vision early in the process by jumping to paint, as it will take longer than you plan.   It will take additional effort and re-thinking to get everything working perfectly so you will want to fully assemble and ride the project once before painting.  Examples being ID of unnecessary frame tabs, parts that don't fit, early decisions that don't pan out, parts that break.  You will have to disassemble one or two times more than you plan, and this will also help reduce the risk of damage.

So here is my list of lessons and observations following this 'restoration'; I hope these tips serve as a helpful guide for your project.  Not necessarily in order of importance:

• be able to summarize your project goal in one or two sentences (there are many decisions to make and this enables a more clear focus on the path forward)
• flesh out your plan before you pull the trigger on parts, etc; use multiple resources and search online retailers and be patient for the right part at the right price
• know exactly what you are looking for before buying the project base motorcycle (between barn-find, basket-case, survivor, or already partly/mostly restored); your time and effort and final cost will vary significantly.  it can be better to pay more up front for a better starting point
• do your research in advance; then do some more.  sample pictures help creative visualization, as do words which describe each aspect of your project
• decide early on what direction you plan to take, between how stock, period, historical vs new, custom, unique, etc
• read up (forums, magazines) on typical restoration tasks so you have a reasonable idea of what you're getting into and can relate what skills you already have or can acquire vs those best left to professionals
• start with the most functional, well-sorted bike possible; if it is not functional and well-sorted, get it that way before tackling the major project elements (esp cosmetic such as blasting, painting, etc)
• ensure all engineering and fabrication are thought-out, executed, and working on the bike before final/complete disassembly for paint, etc
• new parts - check fit and function on the bike as early as possible after purchase/arrival (if it's wrong you can save time and money in getting it right or exchanging/returning it before 3-4 more months have passed)
• don't assume because a part is made for the bike it will fit or connect or work as expected; put it on and try it early on
• expect the project to take 3 times as long as you first predict, and cost twice as much (in my case, paint alone was over half the entire project build cost, after purchase of the bike itself)
• use bins and boxes, with good labels, for parts as they are removed; organization and ensuring parts don't get lost is critical
• cluster similar components together and keep track of where they all are
• use egg cartons or similar small compartment container to label and track small items such as nuts and bolts (you will not remember which goes where at time of reassembly)
• write down sizes, pitch and length of all bolts (sounds like over-kill, but many times when fitting a new bracket or tossing an old part, a new length bolt or washer or nylock will be needed and this makes it easier to obtain from your local hardware store quickly, with less guessing or trial-and-error)
• identify parts (esp many nuts and bolts) for de-rusting, de-greasing, cleaning, etc in batches when possible.  this is dirty work and requires chemicals to which you can minimize exposure if you tackle this job fewer times
• if you're already in there, go ahead and do it now (ie, replacing bearings, seals, o-rings, washers, filters, etc)
• avoid leaving 'easy' things to the end; they aren't always as easy as you expect them to be and can add weeks to the home stretch
• if it's not going well, step away and come back to it later
• buy the right tool for the job, read the directions, and use it; even if it seems a one time use, chances are that you will need it again
• wear proper eye and hand protection when doing any task that calls for it; wash up frequently with a good degreaser
• don't simply trust any 'expert', 'professional' or other tradesperson with your project outcome or expectations just because they appear to have done it before; when specialized work is required, micro-manage every aspect of it.  I had an issue (mostly minor, some not) with every single bit of outside work that I had done (except for paint).  
• there is a first time for every technical job or task and it is a very rewarding part of the build to do it yourself; check the forums, YouTube, etc and try something you haven't done before; trust your past, however, and don't bite off more than you can chew (or be prepared for the cost of replacement)
• have lots of shop towels and a well-stocked, well-organized tool cabinet; keep it that way by returning any tool as soon as you have used it
• spread a sheet of paper (such as the rolls painters use) on your work bench; it helps for dirty parts and to have a place to write down sizes and measurements and parts lists as you go along.  periodically replace it with a new sheet to keep work area clean

Worst/Hardest things:

• degreasing is much harder than it first seems; it takes longer and requires more effort than you think
• derusting is actually much easier and quicker than you might expect; use the right products
• repeatedly getting hands full of grease and/or chemicals, requiring washing over and over
• going back to the same store for the third or fourth time in a week (or a day!) for something you forgot, or did not fit as you had expected
• putting your faith in a part or fitting and finding it does not work, so you have to go back to the drawing board (and/or you wasted time and money on a thing which you'll never get back)
• waiting, and waiting, and waiting.....
• spending stupid money on the one thing you can't do without

One final bit of advice - don't be too anxious to finish the project, or move on to the next step.  It can consume you and alienate those around you.  Have faith that it will eventually be complete, and resist the urge to rush the process.