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1973 R75/5 Rebuild Project Journal

1973 R75/5 Rebuild, Paint Side Cover Horizontal Stripes

I also painted the horizontal stripes on the chrome side covers. I tried the Monza Blue paint from Glausrit but I didn't like how that looked. So, I tried some Dupli-Color rattle can paint and they look better. I may try to paint the side covers yet again as I'm not sure to best handle the curved edges. But they look pretty nice.

Here are a couple of pictures from the write-ups.

Here are a couple pictures.

<a title="Masked Side Cover by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/14255993436"><img src="https://farm6.staticflickr.com/5071/14255993436_d5b2806479_z.jpg" alt="Final Masked Side Cover" width="640" height="480" /></a>
First Attempt at Masking the Side Cover

<a title="First Attempt Painting Side Cover Stripes by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/14459407584"><img src="https://farm3.staticflickr.com/2938/14459407584_fc0dd630e7_z.jpg" alt="First Attempt Painting Side Cover Stripes: Ragged Edges" width="640" height="480" /></a>
First Attempt Painting Side Cover Stripes: Ragged Edges and Easy to Peel the Paint

<a title="Dupli Color Pain by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/14466643685"><img src="https://farm3.staticflickr.com/2925/14466643685_29d0c9048e_z.jpg" alt="Dupli Color Paint Choices" width="640" height="480" /></a>
Second Attempt with Dupli-Color Paint: Two Candidates to Choose From

<a title="Retaped Cover with 1/4 Inch Pinstripe Tape by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/14460520085"><img src="https://farm6.staticflickr.com/5583/14460520085_e569c2a6a7_z.jpg" alt="Retaped Cover with 1/4 Inch Pinstripe Tape Over Dividers" width="640" height="480" /></a>
Second Attempt at Masking with 1/4 Inch Pinstripe Tape Over Dividers

<a title="Final Side Cover by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/14307622330"><img src="https://farm3.staticflickr.com/2919/14307622330_2de503d62a_z.jpg" alt="Final Side Cover Stripes" width="640" height="480" /></a>
Final Side Cover Stripes
 
1973 R75/5 Rebuild, Repair Clear Coat Sand Through

Folks,

Let me start by saying you can't repair clear coat sand through and expect it to last. It won't

That said, I tried repairing my sand through mistakes on the fairing to avoid redoing the clear coat as I don't have enough on hand to shoot it again. And this let me try out the new Devibliss High Flow air line fittings to see how much difference they make in spraying the clear coat. MUCH BETTER!!! I got the atomization I needed and the clear went on glass smooth with very minor orange peel. Another lesson learned.

I followed the techniques I found for doing this so the repair is hard to see. In time, the repaired clear coat will peel. But, I'll get to find out how long this type of repair can last. Live and Learn.

Here is the write-up on how I did this work including some links to very informative YouTube videos I found that show how to do this "you can't repair clear coat" clear coat repair.

  • 51 BMW R75/5 Repair Clear Coat Sand Through
Have a Safe and Relaxing 4th of July.

Here is the sand through pictures and the final result.

<a title="Hazy Areas are Sand Through Spots by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/14280007059"><img src="https://farm4.staticflickr.com/3860/14280007059_93642aba8b_z.jpg" alt="Hazy Areas are Sand Through Spots" width="640" height="480" /></a>
Hazy Areas are Sand Through Spots

<a title="Sand Through Spots by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/14443537916"><img src="https://farm4.staticflickr.com/3870/14443537916_a558770ebe_z.jpg" alt="Sand Through Spots (White Spots at Bottom)" width="640" height="480" /></a>
Sand Through Spots (White Spots at Bottom)

<a title="Clear Coat Repair on Side Panel After Sandi & Buff by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/14335698388"><img src="https://farm4.staticflickr.com/3863/14335698388_1a54788ff7_z.jpg" alt="Clear Coat Repair on Side Panel After Sand, Buff & Polish" width="640" height="480" /></a>
Clear Coat Repair on Side Panel After Sand, Buff & Polish with Pinstripe Stencil Applied

<a title="Pinstripes on Fairing by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/14335674299"><img src="https://farm4.staticflickr.com/3857/14335674299_48287c2937_z.jpg" alt="Clear Coat Repair on Side Panel After Sand, Buff & Polish" width="640" height="480" /></a>
Clear Coat Repair on Side Panel After Sand, Buff & Polish

<a title="Clear Coat Repair on Faring Nose After Sand & Buff by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/14542392983"><img src="https://farm3.staticflickr.com/2921/14542392983_7155be79e5_z.jpg" alt="Clear Coat Repair on Fairing Nose After Sand, Buff & Clear" width="640" height="480" /></a>
Clear Coat Repair on Fairing Nose After Sand, Buff & Polish

Best.
Brook Reams
 
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1973 R75/5 Rebuild, Assemble Windjammer II Fairing

I did a number of projects on the Windjammer II fairing: disassembled the fairing, repaired cracks, removed the old paint, painted it to match the bike (Monza, or Metallic Blue), and painted pinstripes .You can read about that work in these write-ups.

Now it's time to assemble the fairing again and mount it on the bike. I wrote-up how I did this work here.

It required installing the headlight assembly, the side reflectors, new chome edge trim, the Vetter name plate, removing old decals and deep scratches from the windscreen and modifying the fairing bracket so it doesn't gouge the paint on the frame (I hope).

Here are a couple pictures from the write-up.

<a title="New Silicon Seal on Headlight Bracket by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/14547497345"><img src="https://farm3.staticflickr.com/2917/14547497345_f0b9bd67d6_z.jpg" alt="New Silicon Seal on Headlight Bracket" width="640" height="480" /></a>
New Silicon Seal on Headlight Bracket

<a title="Attaching Headlight Retaining Ring by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/14567609313"><img src="https://farm3.staticflickr.com/2938/14567609313_fa3b97405d_z.jpg" alt="Attaching Chrome Headlight Retaining Ring" width="640" height="480" /></a>
Attaching Chrome Headlight Retaining Ring

<a title="Finished Headlight Installation by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/14567609433"><img src="https://farm3.staticflickr.com/2916/14567609433_69050ccfba_z.jpg" alt="Finished Headlight Installation" width="640" height="480" /></a>
Finished Headlight Installation

<a title="New Windjammer Chrome Trim by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/14361037847"><img src="https://farm4.staticflickr.com/3883/14361037847_15e544d273_z.jpg" alt="New Windjammer Chrome Edge Trim" width="640" height="480" /></a>
New Windjammer Chrome Edge Trim

<a title="Heat Chrome Trim to Form to Fairing Curves by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/14547498175"><img src="https://farm4.staticflickr.com/3872/14547498175_a5cda36623_z.jpg" alt="Heating Chrome Trim with Heat Gun to Form to Tight Radius Curves" width="640" height="480" /></a>
Heating Chrome Trim with Heat Gun to Form to Tight Radius Curves

<a title="Adjusting Fairing Edge to Align Chrome Trim by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/14547498355"><img src="https://farm6.staticflickr.com/5566/14547498355_70e5eee5a1_z.jpg" alt="Adjusting Fairing Edge wiht Dremel Tool to Align Chrome Trim" width="640" height="480" /></a>
Adjusting Fairing Edge with Dremel Tool to Align Chrome Trim

<a title="Taping Chrome Trim While Hotcha Glue Dries by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/14547498615"><img src="https://farm3.staticflickr.com/2903/14547498615_60633b926c_z.jpg" alt="Taping Chrome Edge Trim While Hotcha Glue Dries" width="480" height="640" /></a>
Taping Chrome Edge Trim While Hotcha Glue Dries

<a title="Dremel Tool to Trim End of Chrome Trim by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/14547498815"><img src="https://farm6.staticflickr.com/5527/14547498815_61767c73bf_z.jpg" alt="Dremel Tool to Trim End of Chrome Trim" width="640" height="480" /></a>
Dremel Tool to Trim End of Chrome Trim

<a title="Razor Blade to Peel Edge by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/14545959194"><img src="https://farm6.staticflickr.com/5530/14545959194_1881ac8f2e_z.jpg" alt="Use Razor Blade to Gently Peel Edge" width="640" height="480" /></a>
Use Razor Blade to Gently Peel Edge

<a title="LIghter Fluid Loosens Glue by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/14361036797"><img src="https://farm3.staticflickr.com/2918/14361036797_2a29ddc14c_z.jpg" alt="Lighter Fluid Loosens Glue Along Exposed Edge" width="640" height="480" /></a>
Lighter Fluid Loosens Glue Along Exposed Edge

<a title="Novus 3 Removed Scratches by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/14544101141"><img src="https://farm4.staticflickr.com/3867/14544101141_54842e8af6_z.jpg" alt="Novus #3 and Rubbing with Lint Free Cloth to Remove Deep Scratches" width="640" height="480" /></a>
Novus #3 and Rubbing with Lint Free Cloth to Remove Deep Scratches

<a title="Scratches Are Gone by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/14544101561"><img src="https://farm6.staticflickr.com/5318/14544101561_91d516d40d_z.jpg" alt="Scratches Are Gone :)" width="640" height="480" /></a>
Scratches Are Gone :)

<a title="Taping Badge Down While Silicone Seal Sets by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/14545961014"><img src="https://farm4.staticflickr.com/3894/14545961014_aa1c14243f_z.jpg" alt="Taping Name Plate Down While Silicone Seal Sets" width="640" height="480" /></a>
Taping Name Plate Down While Silicone Seal Sets

<a title="Windscreen Gaskets Attached by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/14567610723"><img src="https://farm3.staticflickr.com/2929/14567610723_ca4dae576c_z.jpg" alt="Windscreen Foam Tape Gaskets Attached" width="640" height="480" /></a>
Windscreen Foam Tape Gaskets Attached

<a title="Attaching Turn Signal Stalk and Wiring by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/14544103631"><img src="https://farm6.staticflickr.com/5567/14544103631_ab62a92e43_z.jpg" alt="Hollow Bolt Inside Faring to Attach Turn Signal Stalk with Wiring" width="640" height="480" /></a>
Hollow Bolt Inside Faring to Attach Turn Signal Stalk with Wiring

<a title="Turn Signal Installed by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/14545961484"><img src="https://farm4.staticflickr.com/3911/14545961484_849a703bca_z.jpg" alt="Turn Signal Installed" width="640" height="480" /></a>
Turn Signal Installed

<a title="Gaskets on Lower Bracket by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/14361039367"><img src="https://farm3.staticflickr.com/2926/14361039367_04050c3906_z.jpg" alt="Plastic Edging as Gaskets on Lower Bracket" width="640" height="480" /></a>
Plastic Edging as Gaskets on Lower Bracket

<a title="Fairing Mounted on Bracket by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/14360911738"><img src="https://farm4.staticflickr.com/3869/14360911738_68ca31d1da_z.jpg" alt="Windjammer Fairing & Bracket Mounted on R75/5" width="480" height="640" /></a>
Windjammer Fairing & Bracket Mounted on R75/5
 
1973 R75/5 Rebuild, Final Assembly and Project Completion

Folks,

I completed the rebuild project after 18 months. :)

I documented the final assembly steps in this write-up.

I will post about the the "first ride" around the block separately and include a short video.

Stay tuned.

And yes, it's a let down to be done, but there is a sense of satisfaction at what I learned along the way and the problems I figured out how to solve. I think that's part of the addiction to rebuilding these old airheads.

Here are some "glossy" photos of the completed rebuild.

<a title=". by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/14576011645"><img src="https://farm4.staticflickr.com/3845/14576011645_1a6eacc304_z.jpg" alt="Front Profile" width="640" height="480" /></a>
Front Profile

<a title="Tank by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/14568021846"><img src="https://farm4.staticflickr.com/3926/14568021846_856740d5c4_z.jpg" alt="Gas Tank" width="640" height="480" /></a>
Gas Tank

<a title="Steering Damper & Intruments by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/14552928486"><img src="https://farm4.staticflickr.com/3854/14552928486_a908e734be_z.jpg" alt="Instruments and Steering Damper" width="480" height="640" /></a>
Instruments and Steering Damper

<a title="Front Wheel Hub Cab by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/14596117683"><img src="https://farm6.staticflickr.com/5584/14596117683_bb12e5a538_z.jpg" alt="Front Wheel Hub Cab" width="640" height="480" /></a>
Front Wheel Hub Cab

<a title="Carburetor Facing Front by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/14572654951"><img src="https://farm3.staticflickr.com/2940/14572654951_596dbcb8ea_z.jpg" alt="Left Carburetor" width="640" height="480" /></a>
Left Carburetor

<a title="Carburetor Facing Rear by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/14572655481"><img src="https://farm6.staticflickr.com/5493/14572655481_34124f9ee0_z.jpg" alt="Right Carburetor" width="640" height="480" /></a>
Right Carburetor

<a title="Push Rod Tubes by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/14552928706"><img src="https://farm4.staticflickr.com/3919/14552928706_89605ecfd5_z.jpg" alt="Push Rod Tubes" width="640" height="480" /></a>
Push Rod Tubes

<a title="Low Angle View by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/14589074414"><img src="https://farm3.staticflickr.com/2924/14589074414_675ffd6eea_z.jpg" alt="Engine Badge" width="640" height="480" /></a>
Engine Badge

<a title="Sito Mufflers by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/14574250744"><img src="https://farm4.staticflickr.com/3908/14574250744_df56e26e19_z.jpg" alt="Sito Mufflers" width="640" height="480" /></a>
Sito Mufflers

<a title="Sito Mufflers and Shock by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/14389585417"><img src="https://farm6.staticflickr.com/5524/14389585417_ffd6f571ea_z.jpg" alt="Sito Mufflers" width="640" height="480" /></a>
Sito Mufflers

<a title="Back End by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/14574250684"><img src="https://farm3.staticflickr.com/2931/14574250684_f5123dcb93_z.jpg" alt="Rear" width="480" height="640" /></a>
Rear

<a title="Reflections by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/14404296570"><img src="https://farm3.staticflickr.com/2914/14404296570_4688ea947d_z.jpg" alt="Reflections in Fairing" width="480" height="640" /></a>
Reflections in Fairing

<a title=". by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/14574251364"><img src="https://farm4.staticflickr.com/3875/14574251364_ca9aa5142c_z.jpg" alt="Tool Box, Tools and Tire Pump Installed" width="640" height="480" /></a>
Tool Box, Tools and Tire Pump Installed
 
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In a word... WOW!
We're going to have to coin a new phrase or something to describe a bike lucky enough to have found it's way to your shop!
That bike is nothing short of spectacular. Amazing attention to every little detail. Really, really nice Mr. Reams. Good on ya.

I'm quite sure there are dozens of us who would love to provide you with a cure for your no project blues!
 
1973 R75/5 Rebuild, "Grover's" First Ride Around The Block, July 4th

Folks,

Here is a short write-up on the first time I rode the bike around the block on the Fourth of July. There is a short video at the end.

Yeah, there was a pretty big grin inside that helmet :)

Onward to the next project which is yet to be decided. I'm looking for any of the following bikes to do a build and provide a similar level of detailed documentation:
R60/2
R69/s
(both of the above would get a sidecar at some point)
R80/7
R80/RT
R100/RS (1977-1979 or 1986 on)
R90/S (yeah, sure, maybe if the price is right)

Onward...
 
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In a word... WOW!
We're going to have to coin a new phrase or something to describe a bike lucky enough to have found it's way to your shop!
That bike is nothing short of spectacular. Amazing attention to every little detail. Really, really nice Mr. Reams. Good on ya.

I'm quite sure there are dozens of us who would love to provide you with a cure for your no project blues!

Hi Happy Wanderer,

Thanks for the kind words. It was a labor of love as this bike was my wedding present to my wife. I still have both of them :)

Yeah, project ideas, contributions, etc. are welcome. I am in search of the next bike to restore, build, freshen up.

Best.
Brook.
 
Loved the thread. Interesting, Informative, Enlightening, Detailed, Captivating, Well Thoughtout, on & on etc. Waiting for your next build. Barry
 
1973 R75/5 Rebuild, Another Try Attaching Windjammer Electrical Connector

Folks,

So, at the end of the first ride on Grover, I turned the handlebar to the left to full lock and hear a "crack" noise. It was then that I noticed the turn signal stalks (original length) interfere with the newly repaired electrical connector I had reattached to the fairing. :banghead

Hmm, So, that's why one end of the stalk was bent up, which of course I carefully bent back down again. :doh

So, I tried Plast-aid this time to make the repair. It was reviewed in Motorcycle Consumer News a few months ago. Plast-aid is made in Colorado not too far away from where I live. It is a moldable and formable plastic polymer so you can make things with it and it can be used as an adhesive to bond plastic together, or you can do both. It does not bond to some plastics, like polyethylene, plastic caps on spray bottles, etc. But it does bond to ABS which is what a Windjammer is made of and many motorcycle fairings as well.

Here is my write-up on this repair. I removed the turn signal stalks which I should have done in the first place.


I like the product and it is very easy to work with. I have no affiliation with the company. Your mileage may vary. No warranties or promises of suitability for your purpose is implied ... etc., etc.

<a title="Plasti-aid Kit by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/14434966719"><img src="https://farm3.staticflickr.com/2901/14434966719_ec4687a68c_z.jpg" alt="Plasti-aid Kit-Large Size" width="640" height="480" /></a>
Plasti-aid Kit-Large Size

<a href="https://www.flickr.com/photos/brook-reams/14434966779" title="Applied Plast-aid In Moldable State by Brook Reams, on Flickr"><img src="https://farm3.staticflickr.com/2903/14434966779_f22dc1d75c_z.jpg" width="640" height="480" alt="Applied Plast-aid In Moldable State"></a>
ABS Plastic Patch Epoxyed Across Connector Hole in Side Pocket
 
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Tank Pad Adhesive-3M Weatherstrip Adhisive-FAIL

Folks

A short update on the use of 3M Weatherseal adhesive to attach the rubber knee pads to the tank. When it got hot (94 F) the adhesive let go.

<a title="3M "Gorilla Snot" Edging Adhesive by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/14544104081"><img src="https://farm6.staticflickr.com/5157/14544104081_f5ccc06371_z.jpg" alt="3M "Gorilla Snot" Weatherstrip Adhesive-DID NOT HOLD :-(" width="640" height="480" /></a>
3M "Gorilla Snot" Weatherstrip Adhesive-DID NOT HOLD :-(

SO, I applied a liberal amount of Silicone Seal and attached the pads and used masking tape to hold them in place. The Windjammer fairing uses Silicone Seal to attach the metal headlight bracket to the painted plastic fairing and held for 40+ years. I suspect the kneepads aren't going to come off until I want them to.

Onward.

Best.
Brook Reams.
 
Hmm, So, that's why one end of the stalk was bent up, which of course I carefully bent back down again.

Admittedly, not one of the Vetter crews finest installation details... .. :whistle

Of course, to do it right*, would have required the installer to totally disassemble the front end all the way down to the lower triple clamp and install an appropriate thickness spacer to compensate for the turnsignal bracket. An expensive proposition compared to Japanese motorcycles which simply required the turnsignals to be removed.

I wish that I had noticed that in your "above" shot before you found out the hard way.

* Vetter's Corporate Motto: "First To Do It Right"
 
Admittedly, not one of the Vetter crews finest installation details... .. :whistle

Of course, to do it right*, would have required the installer to totally disassemble the front end all the way down to the lower triple clamp and install an appropriate thickness spacer to compensate for the turnsignal bracket. An expensive proposition compared to Japanese motorcycles which simply required the turnsignals to be removed.

I wish that I had noticed that in your "above" shot before you found out the hard way.

* Vetter's Corporate Motto: "First To Do It Right"

Hi Lew,

Yeah, It was a DUHOOOOO!! moment when I saw that interference between the turn signal stalk and wiring bulkhead connector broke the repair I had made. I never checked to see if the turn signal stalks were going to hit the connector. Oh well, I found a new solution for repairing broken plastic parts.

Best.
Brook.
 
He really is just a regular guy

I met him in St Augustine Fl. at a Riding Into History Concourse event a couple years ago and he is just a regular guy who does amazing things. That Mr. Reams is very much in line with you sir. The Rebuild journal and all its content are simply amazing and very well done. A good many individuals can restore a motorcycle and do a great job but you have gone the extra mile and shared it with hundreds or possibly thousands of very interested readers, along the way you provided a guild and tips for all interested in them. Thank you and thank you so much for all the information and the adventure of Grover's restoration. I am sure Mr. Vetter was equally impressed with your work and may be left speechless after enjoying the Grover rebuild.

Thank you for the adventure
 
I met him in St Augustine Fl. at a Riding Into History Concourse event a couple years ago and he is just a regular guy who does amazing things. That Mr. Reams is very much in line with you sir. The Rebuild journal and all its content are simply amazing and very well done. A good many individuals can restore a motorcycle and do a great job but you have gone the extra mile and shared it with hundreds or possibly thousands of very interested readers, along the way you provided a guild and tips for all interested in them. Thank you and thank you so much for all the information and the adventure of Grover's restoration. I am sure Mr. Vetter was equally impressed with your work and may be left speechless after enjoying the Grover rebuild.

Thank you for the adventure

69zeff65,

I do not know what to say other than thank you for the very kind words.

I found him very down to earth with a wide ranging mind. He is a fun guy to chat with.

Best.
Brook.
 
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