Rebuild Plan

[Striker1423]

So, some here know my bike is on just about every piece possible. Boxed up, torn down and ready for some action. I'd like to get it rideable for the gap this coming May if possible.

1. The Frame:
Stripped of visible rust in spots I could get to, needs painted. New gas tank is at painter getting dents pulled and rust repaired still. Oil tank and side cover need work and paint. Need decal set for tank. I can reassemble it and run it at the gap with the old tank if I need to. My headlamp bucket and ears are bent and ears cracked in need of welding and of course paint. OR, I can replace it with an EMGO lamp from EC. Thoughts?

2. Electrics:
I already have and was running the Vape system. The main harness to run the front and rear lamps is still intact but has a few broken wires I had jumpered to get me by. I either need a new harness I can streamline into what's important, or I need a good used one I can strip down and lose the excess wiring. Keeping things stockish.   

3. Speedometer and tachometer:
I need to get a hold of Mark and coordinate that. Life's been getting in my way recently, but that should be covered. NBD.

4. Drivetrain:
Still running a standard 530 chain and sprockets. All less than 3k on them. Still in good shape. Would be an extra expense to swap, but should I? Chuck mentioned last year he would want to swap the RD250 gearing for his 400 conversion. Makes sense to me which leads me into...

5. Motor:
Obviously seized it and its completely apart. I bought a cooler to ship this bad lad in. So, I can loosely reassemble it and send it on its way. This is the largest expense and is my Achilles heel atm.

The crank:
It's a bit discolored (blued) on the seized side little end rod, just barely blue on the other side. Other than a few flecks of aluminum I found in the bottom end, it looks like it's in good shape. Vito's crank, specifically. Can they be rebuilt? Or should I just fork over for a new one?

Engine cases:
Fully disassembled and top portion vapor honed. Just need to stop being lazy and do the bottom case. That requires elbow grease first.

Cylinders:
I want to do a decent street port. I want to ride it. My friend want's me to just go absolutely bonkers with it. He said: You already have a street bike, just go nuts with it. I'm on the fence about it. I like the idea of additional power, but the ability to still ride it to shows, etc. without dying. Aside from the banshee intakes and crossover tube. The carbs were basic Dave F'd and that's really it.

Pipes:
I have the JL retro's and they work fine for my needs. But, I'll take any input.

Basically, what if anything can I do to expedite thing's? I wanted to write down my work list and take any input on the best course of action you guys take. 

[m in sc]

id send the cyls to john ritter for a stage 1.

as far as the wiring, just wire it from scratch, super easy.

ive run 350 ratios on my bikes. the 400 tranny IS better but we also aren't road-racing. Ive never found it a hindrance.

do the cases while its apart, new crank seals. just because you are already in there. (regardless of new they are)

my .02

[oxford]

If your not planning on getting the frame powder coated drop it off at the local sandblasting place and get it done.  Now is the time to do it and it won't be a huge cost. 

Then epoxy primer and top coat of your choice.

As far as the rest of the plan and your timeline, good luck.  As much as you can do on your own and keep in control the better. 

[SoCal250]

id send the cyls to john ritter for a stage 1.

+1  That was the first thing that came to mind when I started browsing through your list. Good timing too since John just posted about his great deal on his restarted porting work 

[Czakky]

The seat is something to consider. I spent waaay too much time on mine and it turned out very mediocre. Not a ton of $$ but it is focal point...

[Striker1423]

The seat is something to consider. I spent waaay too much time on mine and it turned out very mediocre. Not a ton of $$ but it is focal point...

The seat I recoverer myself last winter. Doesn't look quite stock as it doesn't swoop up in the rear, but it looks pretty good.

The cylinders will definitely be going to John. I guess I'll PM him for some details.