Author Topic: my EV/Eldorado build during the Covid crisis of 2020  (Read 503 times)

Offline randy yocum

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my EV/Eldorado build during the Covid crisis of 2020
« on: July 03, 2020, 11:40:39 PM »
Now this is not your typical 3 year complete ground up restoration of a historic motorcycle this is just me playing around for a few weeks trying too improve on a very good 98 EV that I've owned since 2009.It was a daily driver for several years and a good traveling bike for my wife and I.The thing is.... a nice 2007 Norge kind of dropped in my lap in 2014 and I liked everything about that new machine so the the poor EV got kicked to the curb shall we say and drained of fluids and parked in dry storage,Then in 2016 I bought a good used Stelvio NTX and the Norge got the same treatment as the EV. Anyway I always had in mind that the EV would make a great retro Lemans or V7 Sport ,The parts are readily available and the EV has those great spoke tubeless wheels the Tonti chassis is there,it has fantastic brakes etc.and to top it all off EV'S are basicly not worth that much.I know I can't figure it out either they seem to be underappreciated and under valued.
    So during the last few years I've been seeing allot of these  cafe bikes and retro builds of MotoGuzzi  lemans and V7 Sports so I figure what the hell lets go in the other direction and build one of my favorite bikes an  Eldorado /EV.  I owned a 73 Eldorado I bought as a basket case in 1995, it was my introduction to what is now and has been an obsession with Moto Guzzi's.
    I loved the look and especially the tank of the Eldorado but not the brakes or the handling of that bike.Over the years I've accumulated lots of vintage Guzzi parts,you always know someday they will get used.And another good reason to build the Eldorado style EV is the chassis is pretty much set up for it ,its got the police stand,police bars,floor boards I can tweak the mufflers and maybe not have to replace them.The seat is perfect for the bike I even have a police style windshield which would go well with an Eldorado style bike.
    The thing is I already have two Eldorado tanks one is more like a wall ornament  totally unusable the entire bottom is rusted away the other was solid but full of dents and the chrome patches were dented and rusted.I also for this project bought a dented and leaking Cal3i tank for $50.00 as a donar for my Eldo/EV tank melding.With the Cal3 i I needed a tank that was set up for my Fuel injected bike with space underneath for the aircleaner because I did not want to make any drastic changes to the EV and besides I like the aircleaner under the tank.So I started by cutting the tunnel out of the Eldorado tank and was pleasently supprised at how solid the shell was still.Then since the tank was opened up knocking the dents out was a breeze, next I cut the top out of the Cal3 tank exposing the tunnel and discovered that the cutout for the aircleaner in the Cal3 tank was huge and if I removed the air cleaner black cover on the EV I could cut a bunch of wasted space out of the Cal3 tank and gain a bunch more space for fuel in my new modified tank( the Eldo/EV tank holds an honest 5.5 gallons).It would mean allot more cutting and welding but what the heck what else have I got to do? this is a Covid crisis and I'm stuck at home ,this would be a good use of my abundant free time.So what follows is a few weeks in pictures condensed of the Bike I wanted to build .
   and the first  pictures are of my EV as it looked before and now,the before picture is while traveling with my wife in Colorado  ,I built that trailer by the way,the other is how it looks today.





« Last Edit: July 18, 2020, 10:44:43 PM by randy yocum »
2012 Stelvio NTX
2007 Norge
1998 EV
1981 V-1000 G-5
1997 Ducati 900ss
1983 XL 600R bought new
1978 XS 1100

Offline randy yocum

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Re: my EV/Eldorado build during the Covid crisis of 2020
« Reply #1 on: July 03, 2020, 11:53:03 PM »
part 1 cutting out the pieces and trying to fit them together







 
« Last Edit: July 05, 2020, 10:42:05 PM by randy yocum »
2012 Stelvio NTX
2007 Norge
1998 EV
1981 V-1000 G-5
1997 Ducati 900ss
1983 XL 600R bought new
1978 XS 1100

Offline randy yocum

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Re: my EV/Eldorado build during the Covid crisis of 2020
« Reply #2 on: July 03, 2020, 11:55:42 PM »
part 2 smooth out dents



2012 Stelvio NTX
2007 Norge
1998 EV
1981 V-1000 G-5
1997 Ducati 900ss
1983 XL 600R bought new
1978 XS 1100

Offline randy yocum

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Re: my EV/Eldorado build during the Covid crisis of 2020
« Reply #3 on: July 04, 2020, 12:10:58 AM »
fitting the two parts together I spot welded every seam first as not to warp everything with my wire feed welder.Then went back with oxygen acetylene welding tip to connect everything.to be safe I used red cote tank sealer on the inside after all the welding was done.I've filled the tank 5 times with fuel since  and no leaks.







 
« Last Edit: August 07, 2020, 09:00:48 PM by randy yocum »
2012 Stelvio NTX
2007 Norge
1998 EV
1981 V-1000 G-5
1997 Ducati 900ss
1983 XL 600R bought new
1978 XS 1100

Wildgoose Chase Moto Guzzi

Re: my EV/Eldorado build during the Covid crisis of 2020
« Reply #3 on: July 04, 2020, 12:10:58 AM »

Offline randy yocum

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Re: my EV/Eldorado build during the Covid crisis of 2020
« Reply #4 on: July 04, 2020, 12:28:46 AM »
   Next paint the tank,right from the start I was fearing this step but it wasn't bad.I started with etching primer 3 coats and 400 wet sand between.now your not going to believe this but for the white I used an 8 dollar can of white pearl lacquer spay I bought at Walmart in the automotive section.A couple coats then taped off the top and side panels for the black there again I used Walmart automotive gloss black lacquer.Then came the pin striping straight off the shelf at O Riellys ,luckily I could take measurements from the other Eldo tank I have,.. it made it easy.The Moto Guzzi tank decals I bought from MG cycle.Now I didn't skimp on the clear coat I bought a two part with hardener acrylic enamel.I'm real pleased with how the tank turned out, much better then I had expected and the finish is very hard you can't scratch it with your finger nail,and sooo very glossy. :thumb:
.












some poems on nature
« Last Edit: August 07, 2020, 09:02:14 PM by randy yocum »
2012 Stelvio NTX
2007 Norge
1998 EV
1981 V-1000 G-5
1997 Ducati 900ss
1983 XL 600R bought new
1978 XS 1100

Offline randy yocum

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Re: my EV/Eldorado build during the Covid crisis of 2020
« Reply #5 on: July 04, 2020, 12:46:11 AM »
So what came next was... what to do about side covers,Eldorado side covers would be a logical choice but finding them for the money I want to spend and they wont just snap on they will need extensive modification to work,I even have several sets of the old tool boxes laying around I could attach to complete the look.In the end I put several different ideas to work and they all sort of fell by the wayside.I did have one other cover off a EV California special,same as a Bassa side cover I laid it in place and wow it was a perfect fit all I needed to do is make some mounts and cut the bottom off my seat .As my seat  it was made to fit the triangular EV side cover and the Bassa side cover goes more straight across verses down ,cut seat,make fit,all good.And as luck would have it I found the matching side cover on Ebay it was damaged got it for $50.00 shipped to my door.I tried white paint to match the tank but the covers are pretty big and it seemed like the were competing with my tank too much in white,so I tried black and they just looked right,and blended with the rest of the bike , with the addition of the EV Eldorado decals I had made up at my local sign painting guy.Clear coated I think they turned out just fine.



 
« Last Edit: July 05, 2020, 09:02:12 PM by randy yocum »
2012 Stelvio NTX
2007 Norge
1998 EV
1981 V-1000 G-5
1997 Ducati 900ss
1983 XL 600R bought new
1978 XS 1100

Offline randy yocum

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Re: my EV/Eldorado build during the Covid crisis of 2020
« Reply #6 on: July 04, 2020, 12:51:04 AM »
Another thing I did was create different muffler brackets so the mufflers could go down and in like an Eldorado not up and out like an EV  you can see in the picture what I'm talking about,my new bracket on left and the EV bracket on the right.Just different brackets and turn the mufflers to one side ,no other modification needed.check out the licence plate 2014 was the last time this bike was registered.




« Last Edit: July 04, 2020, 10:00:11 AM by randy yocum »
2012 Stelvio NTX
2007 Norge
1998 EV
1981 V-1000 G-5
1997 Ducati 900ss
1983 XL 600R bought new
1978 XS 1100

Offline randy yocum

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Re: my EV/Eldorado build during the Covid crisis of 2020
« Reply #7 on: July 04, 2020, 01:13:56 AM »
That just leaves fenders I have a set of Cal3 fenders in chrome the rear one bolted right on but the forks on the EV are very unique, the fender needs to fit correctly with the fork brace most fenders will not fit but I found a slightly damaged California Vintage front fender that fits the bill its stainless not chrome but It works for me,most people won't notice the difference.The other thing is I have a complete set of Eldorado ,tailight and turn signals I even have Police Dietz lights I tried bolting on the bike but it just doesn't work for me I kept coming back to that Buck Rodgers taillight and signals from The EV. I really like the look of those lights.So they are staying, after all this is my interpretation of how an EV/Eldorado should look.The last thing I might do to this bike is add the CHIP's style saddle bags I would need the correct chrome mounts but I think I could build the boxes myself.Here's a picture of what I'm talking about.
   The last thing is this bike is a blast to ride,it just turned 70,000 miles I needed to tweek the TPS but everthing else was in perfect tune,I forgot how much low end grunt that engine has ,and its no slouch in the upper rpms either .So the tides have turned and the Stelvio and the Norge are playing second fiddle to this old tried and true classic.And I love all the looks and comments I'm getting while riding it.
 

« Last Edit: July 04, 2020, 10:03:28 AM by randy yocum »
2012 Stelvio NTX
2007 Norge
1998 EV
1981 V-1000 G-5
1997 Ducati 900ss
1983 XL 600R bought new
1978 XS 1100

Offline AJ Huff

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Re: my EV/Eldorado build during the Covid crisis of 2020
« Reply #8 on: July 04, 2020, 08:43:43 AM »
What a perfect rendition! I love it. And such a simpler approach. Has everything I want in a bike!

Great job!  :thumb:

-AJ
'71 Ambassador
'01 California Special
MGNOC# L-753

Offline randy yocum

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Re: my EV/Eldorado build during the Covid crisis of 2020
« Reply #9 on: July 05, 2020, 05:13:23 PM »
Thanks man!! I was in my shed today  and saw something curved and gleaming like chrome I dug a little deeper and pulled out what looks to be a descent set of rear crash bars for probably a Cal 2 .I wonder if I should try and fit them to this bike ,or is that over kill?
  What do you think?




« Last Edit: July 06, 2020, 02:33:09 PM by randy yocum »
2012 Stelvio NTX
2007 Norge
1998 EV
1981 V-1000 G-5
1997 Ducati 900ss
1983 XL 600R bought new
1978 XS 1100

Online Canuck750

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Re: my EV/Eldorado build during the Covid crisis of 2020
« Reply #10 on: July 05, 2020, 07:47:12 PM »
This is very cool :thumb:

Excellent skills making that gas tank :bow:

Offline Blaufeld66

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Re: my EV/Eldorado build during the Covid crisis of 2020
« Reply #11 on: July 06, 2020, 02:43:05 AM »
Congrats, your EVEldo is very nice!!!  :thumb:
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Offline Don G

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Re: my EV/Eldorado build during the Covid crisis of 2020
« Reply #12 on: July 06, 2020, 01:46:02 PM »
Beauty! I have been considering doing something like this for a while now, you did good. :thumb:  DonG

Online wirespokes

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Re: my EV/Eldorado build during the Covid crisis of 2020
« Reply #13 on: July 06, 2020, 09:37:56 PM »
Cool job! Very well done.

I am curious how you managed to know where to cut the two individual tanks so they'd mate up so well. It's not like they're two identical tanks where all that's needed is measuring back and up.

Would you mind explaining your process?

Offline SED

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Re: my EV/Eldorado build during the Covid crisis of 2020
« Reply #14 on: July 06, 2020, 09:53:06 PM »
Cool job! Very well done.

I am curious how you managed to know where to cut the two individual tanks so they'd mate up so well. It's not like they're two identical tanks where all that's needed is measuring back and up.

Would you mind explaining your process?

Yeah - nice work.  How did you get the tanks to match?  You gas welded them?!   :bow:

What is the tool in the dent removal post?

Looks great!
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Offline randy yocum

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Re: my EV/Eldorado build during the Covid crisis of 2020
« Reply #15 on: July 06, 2020, 10:04:09 PM »
  Hi Wirespokes ,there is no real magic involved in fitting the two tank halves together , allot of it is trial error,I didn't know from the beginning how it was going to turn out,I kinda got the general shape and starting place figured out and then kept whittling away at the excess material till things fit close enough to suite me.As you can see in these extra photos it's not always a perfect fit, there were gaps that needed to be filled in along seams .But working with thin sheet metal has its own rewards you can cold shape or in my case since I had the torch going anyway I would tack pieces in place then get them cherry red and lightly pound them into shape which for me was simpler and it helped to get things just right.This tank took several days of work to complete, it was fun,but not sure I'd want to do another.
 I hope I explained it well enough,
To answer Seds question its a planishing hammer I bought at Harbor Freight $150.00 its pneumatic,It works really well on thin metal it flattens dents in a hurry and if you want to create curved pieces it will do that too just keep pounding and moving the metal till you get the shape you want.There are plenty of you tube videos out there you can watch.
   You know Sed this technique and tool only worked  because I cut the tank wide open everything was easy to get to, in a normal situation with a solid tank you couldn't get the tool in there.




 
« Last Edit: July 11, 2020, 07:02:06 PM by randy yocum »
2012 Stelvio NTX
2007 Norge
1998 EV
1981 V-1000 G-5
1997 Ducati 900ss
1983 XL 600R bought new
1978 XS 1100

Online wirespokes

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Re: my EV/Eldorado build during the Covid crisis of 2020
« Reply #16 on: July 08, 2020, 12:37:59 PM »
Thanks Randy. I get it.  :thumb:

Offline ivantheterrible

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Re: my EV/Eldorado build during the Covid crisis of 2020
« Reply #17 on: July 08, 2020, 03:54:26 PM »
very nice job randy!

could you have made the Eldo tank fit if you had removed the airbox? (I understand that you didn't want to)

Do I understand correctly that you removed the top of the airbox? If so, would that have been enough to fit the eldo tank?

Thanks

Offline s1120

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Re: my EV/Eldorado build during the Covid crisis of 2020
« Reply #18 on: July 09, 2020, 02:34:42 PM »
That is so cool!  I love the vision.
Paul B

Offline randy yocum

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Re: my EV/Eldorado build during the Covid crisis of 2020
« Reply #19 on: July 11, 2020, 07:18:50 PM »
To ivantheterrible Yes, I cut the entire black plastic air box top cover off just leaving the rim that holds the air cleaner down snug to the air box.The first picture shows how the air filter and air box as they look today,minus the tall black cover.The bump in the under side of the tank becomes the new air box shroud or cover.I whittled the large bump in the tunnel of the fuel tank down ,it was taking up way more space then was needed and I estimate I picked up 3/4 of a gallon of gas by doing this.you can see that in the second picture.





 
« Last Edit: July 22, 2020, 10:34:03 PM by randy yocum »
2012 Stelvio NTX
2007 Norge
1998 EV
1981 V-1000 G-5
1997 Ducati 900ss
1983 XL 600R bought new
1978 XS 1100

Offline ivantheterrible

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Re: my EV/Eldorado build during the Covid crisis of 2020
« Reply #20 on: July 11, 2020, 09:22:38 PM »
thanks Randy

 

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