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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...

    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.
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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
    bigrob's Avatar
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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.
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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....
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  10. #10
    Dr. Shop Teacher's Avatar
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    Getting the frame prepped

    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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