Now she is back together after a lot of work and waiting for stuff to arrive from all over the planet. Bits replaced were: valves, rockers and valve lifters (all good used). New parts were: master cylinder, steering head bearings, gaiters, carb needles, filters, coils and points. All precious fluids replaced. I added some idiot lights to the headlight bucket to replace the inadequate ones in the Acewell instrument. The wiring is getting tidier, but there is more to do there. I’m thinking of shifting part of the rat’s nest to the now available space under the tank.
Lots of things were fixed, tweaked, bent to my will or simply tidied up. Frame and subframe got a satin black powdercoat and the other paintables are matte black (Killrust Epoxy Enamel rattle cans). I really like the look – the matte reflects light in interesting ways – under full sun there is a golden sheen. Here under light cloud, it looks silvery. I baked the paint well (by the wood heater) between coats and it seems quite robust.
Fixing the side stand was an interesting exercise. The tip of the stand had at least 50mm of slop. The pin had detached from the frame and had carved oval holes in frame and stand.
I used a 14.5mm reamer to make nice round holes and lathed up a new steel pin – interference fit into the frame hole and sufficient clearance for grease in the stand hole. This got a dob of weld to the frame, as per original.
The poor worn centre stand also got some treatment. I cut 12mm wide slots in the bottom curve (where the metal had worn through) and welded in some 3mm steel, curved to suit.
The alloy bits received the Rub’n’Buff treatment after a thorough clean, using the Pewter flavour.
The headers and mufflers were a surprise - all that brown crusty shit polished off. I started with kerosene, then a stainless steel 'cleaner' (Sulphamic acid) and a scotchbrite pad. Then used a buffing wheel on my bench grinder with a s/s polish, and they came out gleaming like new. Headers are now developing a golden glow after first rides.
For those who may be concerned about loss of patina, rest easy. Let me assure you there is still sufficient evidence of Brunhilde’s hard life, at my hands and those of previous butchers. All her scrapes are there, the rusty nuts and bolts with the corners off, the chisel marks in the exhaust nuts, the tarnished carb clamps, etc, etc.
Some more pics.
Now I’m thinking I would like to have gloss black pinstriping on the tank. I would also like to make a somewhat shorter and lower seat. Being a person of sensible height, I'm finding that the last couple of inches on this police seat are not used. I'll be making a new rear rack out of some nice timber, all nicely mortised and tenoned and epoxied and varnished to within an inch of its life. There should be more wood on old airheads.
I’ll offer some advice to others contemplating a complete teardown:
There are a lot of bits. Don’t worry, they all go back where they belong. Work methodically, take lots of pictures, make notes, label wires with little stickers. Egg cartons make good containers for nuts and bolts, etc. Shove the invoices away without adding up the numbers. Get used to the fragrance and flavour of your favourite solvent cleaner (mmm, kerosene). Use a barrier cream on your hands. Explain to your significant other that you may be preoccupied at times, that you are having an affair of sorts but it is not to be regarded as any sort of challenge and that you will reappear eventually with that old twinkle in your eye.
Some acknowledgements:
Thanks to Jeff of Albury (ME109) for the gorgeous RS front mudguard, kindly donated.
Thanks to George of Bethanga (Siegfried) for use of lathe and other tools, also welding and electrical troubleshooting.
I reckon it does too. 
