I started this build last month thinking this is a straight forward build, nothing fancy just a complete rebuild, paint job engine rebuild, the wheel had the hubs ultra violet inspected for any cracks as I didn't want to have the rims painted or anodised keep as is as I'm using the bike for a long tour. The Hubs have been powder coated.
After having the frame powder coated I'm starting to notice lugs missing, I should have inspected the frame before I sent it off to be painted, the lugs are the ones where the rear fender attaches to, there are the two side ones and the large rear lugs, I've noticed the the bottom tree is not the original the front cowel attaches to the frame then attaches to the bottom tree the m5 bolt is about 30mm To far over, not to much of a problem I can make a bracket then paint,
I think I'll continue building the bike when I get the wheels on then I'll make the lugs and weld them on and try matching the powder coat with a red paint.

I'm not one for posting in great detail on a rebuild, just a few photos as I progress. If it intrests anyone.




I kept the rims as is but had the hubs powder coated and extra strong spokes fitted




The shock was in good order, the piston was like new, so I just powder coated the spring and painted the body other than that that's it, I did think about putting something with a good name tag on, then I thought why if I'm doing such a long ride on a bike like this why would I want to start putting all these name parts on, I might as well go and buy a new ktm 690, not likely,



I must say the guy did a great job on the powder coating.

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Lovely job........but,
You appear to building this bike in the living room!
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Its the conservatory actionman, the misses said she doesn't see me much now with me doing the rebuild for my trip next year, so she let me in the house with this one, its just an old rug I put down to protect the floor from scrackes,

Tis looking good

I like it, keep pics coming.

Looking good.....oh for mine to look pretty again....

Thank you guys, I rebuilt the fork with the same springs they were with in spec, I was surprised how well they looked when I took them apart, the fork oil was very dark so must have been in for a time. I bought the bike off eBay for £600 so I had no idea where it's been what's been done to it, the lad did say it's stud for 4-5 years as he couldn't get it started, . Mileage is 37000
After a quick blast with air gun and flushed some fresh fuel through it kicked over after 9 kicks, just spilt oil out from the centre gasket other than that it's fine.

I've used continental tkc 80's for a long time now on a BMW 1150 gs there are great for touring and off road, I get about 5000 miles to the rear and 1000+ to the front, there will do a lot more on the tenere as not as much weight,
They do a top speed of 112 mph with tyre pressure upto front 38 back 40 off road I run at 22 26, giving loads of grip back and front.
I've never used these on a tenere, I've just fitted them on the rebuild I can't see any problems with clearances, I can put my fingers all the way round the swing arm,
Fitting is not bad on the front it went on nicely, the back went on with a bit of a struggle, I used a set of tyre levers that I would Carry on tour about 240mm long I managed fine, in my work shop I've got 500mm levers that I use,
Over all I'm very pleased with the tyres.

https://www.dropbox.com/s/5b7y7crsvkrbn ... 8.jpg?dl=0

https://www.dropbox.com/s/9md13wp900rla ... 9.jpg?dl=0


Finally got my plastics and tank back, decided to go go for a much stronger front fender as I like to carrie two inner tubs on there and the Xt will not manage the weight for such a long distance off road.
Bikes looking cool, I've ordered 34L decor, put that on then have the panels lacquered.
I'll get some nice photos