This page will cover the disassembly, inspection and restoration processes!

Front Fork Assembly

Front Lower Fork and Brake Hub Assy

This is a picture of the front lower fork and brake hub assembly in the as-is condition purchased.

Front Wheel (Rim)

This is a picture of the front wheel (rim) in the as-is condition purchased.

Front Wheel Assembly 10/26/2023

This is a short video showing the process of preparing the front wheel assembly, including rims, brake assembly and speedometer gears.

Fork Assembly 10/26/2023

This is a short video of covering the fork including the handelbars, fender and headlight assemblies.

Look Ahead

This area will present the new parts as they roll in and await being installed on the bike. The Alpina is a fairly rare bike so parts are hard to find and once found, very expensive. A challenge that can be very rewarding!

Week 2 Update 11/2/2023

This is a weekly progress video and will cover things like parts received or re-assembly of items in-work or disassembly of the next work areas.

High-speed polishing tool...

Results for the brake hub and speedometer gear assemblies.

Week 3 Update 11/8/2023

Still making very good progress on the bike and finding and receiving parts. The needs list is growing!

Some additional information on the state of the "wiring harness." I will definitely be replacing the entire wiring harness on this bike!

Week 4 Update 11/14/2023

Finalizing the frame for sandblasting and powder coating.

Parts Nuances - 11/19/2023

WIRING HARNESS

I received the new wiring harness for my Bultaco but it was purchased from a company in Spain so the installation instructions and labels are all in Spanish (pictures above and to the right).

Fortunately Google does a failrly nice job translating Spanish to English. I typed the paper document in Spanish into a Microsoft Word document and then used Google Spanish to English for translating sentenances and words and took pictures of the diagrams and pasted the into my doocument (2-3 hours of work). The final document (Wiring Harness - English) is next and should be good enough for installing.

Wiring Harness - English

Download PDF

Front Fork Removal - 12//14/2023

Update from the week before Thanksgiving. The new tool for removing the front came in!

I have received all the parts I have ordered to date. Here is a visual of many of those parts .

If you are wondering why I decided to buy newp parts vs. repairing or restoring the old...

Removed the Engine - 3/3/2024

Engine is on the Bench

It took more work than I expected but once moved in the correct position the engine came right out!

Bare Frame - 3/3/2024

Ready for sandblasting and powder coat!

I have a few remaining items to remove from the frame before sending out for sand blast and powder coat. The swing arm does not want to come off so it will need some convincing!

Outside Work Sandblast & Powdercoat - 3/12/2024

Loaded up the truck

MTS COATING SERVICES, INC.

Loaded up the truck

Talked to MTS Coating Services, a local shop that does sandblasting and powder coating, about finishing up my frame, frame components and exhaust system. Should be ready by early April.

smaller parts

MTS COATING SERVICES, INC.

Loaded up the truck

Chain tensioner, rear brake lever, foot peg and top engine mount.

MTS COATING SERVICES, INC.

MTS Coating Services, Inc. in Manhattan, KS. Contracted for: sandblasting all parts; Ceremic coating the exhaust with a flat black; cut off the welded foot peg on the left side of frame; weld the kickstand mount; remove the swing arm and Powdercoat the frame and frame components (including swing arm) metalic silver.

Back from Sandblast & Powdercoat

Exhaust (ceremic coating)

Frame, Swingarm & kickstand

Footpeg

Frame, Swingarm & kickstand

Footpeg

Outside Work to Paint - 4/2/2024

gas tank & side covers

tank stickers and color codes

Talked to Scott at RC Auto Body to get a quote for painting my gas tank, sticker placeent and clear coat over everything. A couple of weeks to turn around.

tank stickers and color codes

Gas tank and side cover stickers. Bultaco colors, tank and covers Bultaco Blue. Tank trim Bultaco Silver with black pinstripe on the top side like picture below.

color & sticker placement

Example of how the finished product will look once completed.

RC Auto body

color & sticker placement

RC Auto Body shop in Manhattan, KS. Contracted for: Sanding and preparing gas tank and side panels for Bultaco Blue paint, Bultaco Silver stripe along bottom of gas tank with black pinstripe on top between silver and bule on both sides, sticker placement and clear coat on top of all.

Discovery of Tank History

Tank As-IS condition

Under the decal

Tank As-IS condition

Back from Paint - 4/22/2024

gAS tANK LEFT SIDE VIEW

gAS TANK RIGHT SIDE VIEW

gAS TANK TOP VIEW

sIDE PANELS LEFT & RIGHT RESPECTIVELY

Rear Wheel & Brakes - 4/10/2024

Rear Wheel - Before

Rear Wheel & Spokes - Before

Rear Wheel - Before

The previous owner, used black spray paint on the rear wheel, hub and spokes. What was not painted was embedded with heavy duty grime.

I will be ordering new brake shoes and a new 42 tooth sproket for the final re-assembly.

Brake Hub - Before

Rear Wheel & Spokes - Before

Rear Wheel - Before

I had to use paint remover for the first pass of cleaning up the wheel and hub assemblies. Like the front brakes, the rear brake shoes were frozen solid and required a lot of penetrating oil and TLC for removal.

Rear Wheel & Spokes - Before

Once all the paint had been removed, I used my tried and true process, WD40, green scratcher and steel wool to clean. If this was a museum resto, I would replace the spokes.

Then I used the Mothers aluminum polish with the lamb's wool polishing pad for the shine.