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  1. #1
    Dr. Shop Teacher's Avatar
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    Manco Thunderbird Budget Build

    Started on my second bike project this week--a Thunderbird I picked up for 50 bucks with a 5hp GC160 on it. Lots of work to do, so thought I'd post the progress on this project. This will be a rider, I broke the bank with my Bird Thunderhawk...so this is on the cheap.

  2. #2
    Dr. Shop Teacher's Avatar
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    Before the fun begins...

    -img_0488-jpg Here's the bike before teardown
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  3. #3
    Dr. Shop Teacher's Avatar
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    What lurks in Japanese Crankcase

    A nice looking Honda GC160 from a power washer was on the bike...it ran once I cleaned and got the water out the carburetor. I was surprised when I went to change the oil and got this...oh well, i'll just fill it and run it and change it a couple more times. -img_0499-jpg
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  4. #4
    Not so mini bike's Avatar
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    I've seen that a couple times. Good luck with the build.

  5. #5
    Dr. Shop Teacher's Avatar
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    Thanks, the engine has more surprises in store for me.

  6. #6
    OND's Avatar
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    I'm Subscribed . Good Luck !
    Lil Indian, Ruttman, DB30, Warrior, lil Bill, EZ Rider, Savage SSC , Powell

  7. #7
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    Great project !
    I used a gc160 on my arctic rat project ,the front exhaust was a challenge but well worth the effort

  8. #8
    Dr. Shop Teacher's Avatar
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    Never ending engine surprises

    Honda never intended for GC160 mufflers to come off, it seems. Both bolts snapped off even with judicious application of heat. Nothing like a trip to the auto parts store for helicoils and a bottoming tap (mine are through taps). Got the new throttle control from boats.com and will need to tinker with governor and return spring. -img_0491-jpg -img_0494-jpg
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  9. #9
    Dr. Shop Teacher's Avatar
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    This bike is a bit easier than my first one....

    This was what my first bike looked like.... -img_0397-jpg
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  10. #10
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    Getting the frame prepped

    -forks-jpg -frontwhl-jpg Have been working on stripping paint off of the frame. Manco must have sprayed enamel right onto bare metal as it looks like there is no primer at all--no wonder it rusted! I'm using Kleen Strip Aircraft Paint Remover, and this stuff is quite good. I have about six hours into stripping and priming now.
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