2005 body rebuild
 

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 :)
https://images84.fotosik.pl/404/f7eddd68ecf81515gen.jpg

GG
 

At the moment Gas Gas is completely disassembled.
https://images83.fotosik.pl/405/ce3745b2e23c64bdmed.jpg

Today I took the frame and swingarm for sandblasting and powder coating.
That`s how my frame and swingarm looks like before painting :)
https://images81.fotosik.pl/405/7880aac21fc68469med.jpg
https://images83.fotosik.pl/405/bb6d9f65fd620361med.jpg
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
https://images82.fotosik.pl/405/9bcbc8da7cd130cdgen.jpg

I received today from service my front suspension Sachs 48 - rebuilding cost 100 eur
https://images84.fotosik.pl/405/793d13c3e830eef0med.jpg
Rear shock was in worse condition, it was necessary to replace the head and the acetabulum - approximately 140 eur
https://images81.fotosik.pl/405/27115158506cc2f1med.jpg

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
https://images83.fotosik.pl/413/960a08de3b805547med.jpg
Steering head bearing set -20 euro
https://images83.fotosik.pl/413/bb40797c54fa7882med.jpg
Silicon hoses - 40 euro
https://images82.fotosik.pl/414/5055317400c5d9c5med.jpg
Brake pads - 33 euro
https://images83.fotosik.pl/413/b58ef855685fc412med.jpg
Air filter - 10 euro
https://images83.fotosik.pl/413/a96bf63ccc6ed05emed.jpg
New bolts, screws - as I disassemble something I like to assemble using new screws :) few euro
https://images82.fotosik.pl/414/10b08169fa3fb3c8med.jpg
Front sprocket - 16 euro
https://images84.fotosik.pl/413/2b82d85b36d5e532med.jpg

Head mask rubber holder - 5 euro
https://images83.fotosik.pl/413/12a8c3e33e13af88med.jpg
Brake sensor, screws, exhaust springs etc another 10-15 euros
https://images82.fotosik.pl/414/5761445220ff6196med.jpg

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.
https://images82.fotosik.pl/416/9814af35c11cd49agen.jpg

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 :)
https://images82.fotosik.pl/416/77a2d10749e86056gen.jpg
I bought as they call it "MOD KIT EXHAUST VALVE" for 59 euro
and and again some screws, washers, springs, etc.
https://images84.fotosik.pl/416/87e4cfd536f5e0e8gen.jpg
Due to the fact that I had very much tired radiators I bought new with leaves
Radiators 160 eur
Leaves/ radiators rack - 8 euro
https://images84.fotosik.pl/416/8a10a0dfb33e40b4gen.jpg
https://images83.fotosik.pl/416/81306682e17fec87gen.jpg

This is the same kit I want for my 2005... can't wait to see the end product!