2005 body rebuild

Gleiwitz

New member
I started rebuild my Gas Gas and wanted to share it with you :)
I can publish the costs so you could estimate costs of this kind of reconstruction.
This was my Gas Gas a week ago :)
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Last edited:
GG

At the moment Gas Gas is completely disassembled.


Today I took the frame and swingarm for sandblasting and powder coating.
That`s how my frame and swingarm looks like before painting :)
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When I will pick up in next week painted elements I will immediately share photos with you.
 
gg

When it comes to costs, at the moment, I spent 540 euros for transformation kit purchased from motocrosscenter.com
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I received today from service my front suspension Sachs 48 - rebuilding cost 100 eur

Rear shock was in worse condition, it was necessary to replace the head and the acetabulum - approximately 140 eur
 
I'm still waiting until frame and swingarm will be ready so in the meantime I ordered some parts :) one package already came and two more still on the way :)
Swingarm repair kit - 53 euro
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Steering head bearing set -20 euro
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Silicon hoses - 40 euro
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Brake pads - 33 euro
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Air filter - 10 euro
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New bolts, screws - as I disassemble something I like to assemble using new screws :) few euro
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Front sprocket - 16 euro
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Great thread love following ones like this!! Good luck

will you be spraying/painting/covering the clutch cover? I think it makes such a difference when theyve been done!
 
Thanks a lot imsimon !
I have to admit that I also liked to read such thread therefore preparing rebuild of my Gas Gas I decided to share it with you.
Turning back to your question, of course I bought both new covers :) 9 euro and 32 euro.


I have a lot of new parts for the engine but take care of him later. First, I want to finish the reconstruction of body.
 
Using the promotion at that time motocrosscenter.com had I bought for 190 euro new carburetor :)

I bought as they call it "MOD KIT EXHAUST VALVE" for 59 euro
and and again some screws, washers, springs, etc.

Due to the fact that I had very much tired radiators I bought new with leaves
Radiators 160 eur
Leaves/ radiators rack - 8 euro

 
mtnmanseth
I love Suomi graphics, looks so clean and fresh :)
I can wait to see my frame in white paint. Finally I will be able to start assembling :)
 
Unfortunately, I'm still waiting on the frame and swingarm :( So i still buy something new :)
Chain guide - 9,95 euro

Rear damper bearing kit - 9 euro
T0201495 screws - 2 x13 euro
T0214110 screw - 15 euro
Tie rod repair kit - 35 euro

Swingarm axle - 28 euro
Nut - 5 euro
Every Gas Gas users knows that it is hard to remove it :) unfortunately I damaged old one hehee

Swingarm rubber, radiator bushings, some other screws - 25 euro
 
Is it the same light for the 11 and 12? I have the 11 but don't like it much would be easy if I can just buy the new headlight plastic
 
Is it the same light for the 11 and 12? I have the 11 but don't like it much would be easy if I can just buy the new headlight plastic

The lamp itself fits perfectly. At least the one I got together with the transformation kit.





You will have to also replace the front fender because these lamp mask have different fixings.
 
Does your new fender have the 2 pins that go into the head lift built in to it?
Or are they a separate section part?
 
The lamp itself fits perfectly. At least the one I got together with the transformation kit.

You will have to also replace the front fender because these lamp mask have different fixings.

I will have to work something else out anyway as I have a yzf front fender on mine
 
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