Unofficial Royal Enfield Community Forum

General Discussion => Campfire Talk => Topic started by: AgentX on September 11, 2011, 03:58:29 pm

Title: My New Plan
Post by: AgentX on September 11, 2011, 03:58:29 pm
So, I am aiming to remain an Enfield rider when I return to the US.  Would like to have a bike that's come back from India with me, just for sheer sentimentality/originality.  But my bike is a 2010 350 model, which can't be imported and is really underpowered for use in the US anyhow.

Here's my new plan.  Would like some feedback if anyone has ideas on feasibility or methodology.

I am going to find a 1988 or older bike, which will make it 25 years old and easily importable to the US as an antique when my time in India is up.  Will look for a 500, but they are very, very rare here.  Thus, planning on finding a 350.  I'll just have to adjust to right-foot shifting, I think.

Would like a low-brow cafe style bike, a la Project Badger, but I think the riding position would be a nightmare for Indian traffic.  So I'm going to try for something that looks like the love child of a three-way between a flat tracker, the McDeeb Six Days scrambler and the Bulletproof Badger conceived after a night of heavy drinking in a bowling alley.  

Will get rear-sets and flat-track bars, probably keeping the stock tank.  Probably lose the casquette and go with a Thunderbird triple clamp setup to get the bar mounted a bit more forward than standard Bullet positioning.  Very minimalist overall, small round headlamp, likely dropping the toolboxes and going with a very chopped front fender in flat black.  Gauges mounted to the bar with simple clamps, old-style polished metal controls and switches.  Don't need turn signals here but the jury's still out on those--probably best to have some on when importing to the US, at least.

Still trying to decide whether to chop down a stock seat and fender to make it look like the Six Days but with a minimal stub of a fender, or go for a fiberglass tail section.  (The one thing about Bullet styling that bothers me a lot is the stepped seat.)  Also debating a low or high exhaust setup.

(I want to avoid the nightmares of proportion that is the modern EFI Fury, in any case!)

Anyhow, more importantly, for return to the States, I hope to also bring back the necessary parts (with guidance from Ace Cafe) to convert my engine to a 535 Fireball.  At which point I can also add clip-ons and maybe a cafe tank, and get some suspension updates (cartridge emulators and a brace for the fork, and modern shocks with adjustable damping for the back).  Might try to throw a 5-spd box on it, too.


Here's a pic which inspired me a bit.  Was also intrigued to hear that they're going to set the Badger itself up for flat-track.

(http://www.flickr.com/photos/az-johnny/5561337340/)

Edit:  Pic's not working but I can "open in new window" by right-clicking to get it.


Am I making this harder than I have to?!  Am I bound for failure somewhere?  Am I going to regret turning a classic old Bullet into a personalized freakshow of a bike :D ?
Title: Re: My New Plan
Post by: Kevin Mahoney on September 11, 2011, 04:58:52 pm
As far as modifying your bike goes I am totally behind your ideas. As an American you know it is  your duty and in your DNA to fool around with the bike and modify to suit you and you only.

Beware of a 1988 or older 500. They were not made then and a sharp customs agent will bust you. The only way you might find one is to find one that has had the case bored out and a 500 top end installed. Also beware of a "good as new restored" engine. Buy the thing but be prepared to rebuild it yourself. For what it is worth a 500 will bolt into a 350 frame (more or less).

If you avoid fake Indian paperwork (extremely common) and do a legitimate import of an older bike you should be fine. If it is fake paperwork (a newer bike with older bike documents) you might be busted and the bike seized.
Title: Re: My New Plan
Post by: AgentX on September 11, 2011, 05:10:27 pm
I didn't know they didn't make 500s then...350 it is!  And yeah, I'm really wondering if there will be legit paperwork with any old bike (it's bad enough with my brand-new one!) but I was planning on getting a genuine letter from Chennai affirming the model year of the VIN on whatever frame I end up getting.  Figure the bill of sale and vehicle registration will be enough to prove my ownership of the bike, which should be the only other thing I need to show.  Will get in touch with some other forum members who've tried this in the past when the time comes.

(I work in anti-fraud stuff, so I'm going to be particular about the paperwork...)

Ace Cafe told me I'd need a 500 head, alloy barrel, and crankcases to make the 350 into a Fireball...plan on pursuing that once I finally have a bike and things are underway.

Thanks for the advice!
Title: Re: My New Plan
Post by: jartist on September 11, 2011, 06:25:18 pm
Good luck with your project- sounds epic!!! There's bound to be a few hurdles along the way but well worth sticking with it. When it's all sorted you'll end up with an heirloom bike and the envy of all here in the states. Its really cool when there's history and a special bond between man and machine when plans like this come together!
Title: Re: My New Plan
Post by: Maturin on September 11, 2011, 08:29:35 pm
http://www.royal-enfield.net/articles/articles.html

On this page you´ll find several articles about the Bullet. The most interesting one is the last, written by Royce Creasey, you may know it already.
In case you don´t: here´s an excellent description how to tune up a Redditch´ 350. I guess most mods will work for an Indian bike aswell,  just in case you have fun to do something noone else does. Anyway, Royce´ articles always have been a lot of fun to read. Regards
Maturin
Title: Re: My New Plan
Post by: AgentX on October 01, 2011, 05:56:24 pm
Wow, almost forgot I'd actually posted this!  My mind is still a mess thinking of the possibilities, but I'm excited.

Thanks for all the encouragement and input so far.  Really appreciate the articles, Maturin.  danke sehr.

Main task now is finding a bike to begin the project.  Everything in India takes a long time and hunting down a good bike for a good price is a challenge.  Although with the work I'm planning on doing, I should probably find an old barely- or even non-running bike and just tear down and rebuild from the frame up.  But even then, India is always about the search.


I would love to be ordering every little bit I want to use online and have it ready when I get the bike, but it's sort of a catch-22 on where to start.  Every decision depends on something else, and I probably need the bike in hand to finally take a bit and see where I can go with it.  I have started talking to one of the guys on Ebay about a custom seat, though...

Biggest debate for me right now is to use a flat bench seat with a severely bobbed fender or a cafe/dirt track style tail.  I am leaning towards the bench but we'll see what the custom maker says.  Really love this seat (http://www.pipeburn.com/store#ecwid:category=731142&mode=product&product=2920486) but the cost and the real leather cover are probably not what I need right now, so trying to get it done either locally or by the ebay guy.  This leather and fiberglass (http://www.motolanna.com/ourshop/prod_966157-Seat-Cafe-Racer-Studs-CWP.html) unit is pretty cool, light, and has great reviews, too, though.  In any case, will be an adventure mounting the SR500 seat pans to the Enfield.

Will stop posting about my dabbling for now, but when I have something going I'll try to keep everyone in the loop on the build.
Title: Re: My New Plan
Post by: AgentX on October 22, 2011, 03:02:07 pm
OMFG.

(http://i6.photobucket.com/albums/y218/MikesBikes/IMG-20111022-00018.jpg)

My ride is a surplus military 1977 model year which served in Kashmir.  Still has its military registration/serial numbers on the fenders and the battalion logo on the tank.  Pretty busted up around some of the periphery but all told, she's in great shape.  Looks like a bunch of privates with a bucket of OD green housepaint were told to re-finish it every few months of its life.


Not in running shape now but will be rebuilt; unfortunately it's gonna take a few months with the mechanic I'm working with.  He's a busy man in demand, but he's not going to balk at what I want to try, which is gonna seem pretty weird to most Indian eyes.  And he seems to have a clue about what he's doing.

It is going to be a mishmash of styles, but I really want to keep the bike's patina and do service to its heritage while making it into a real hot-rod.  I'll hang on to all the original parts in the event I want to do a more classic restoration someday.

So, right now, I plan on:

Putting a front TLS brake (OD green with red laquer between the cooling fins, maybe drilled a la Project Badger for venting)

New 5-speed transmission box

New rear shocks (RE stock with the piggyback reservoir)

28mm Mikarb, K&N pod filter, might experiment with a snorkel-style intake like Ace was using once the bike is running.

upswept megaphone muffler, pipe wrap (once header is de-rusted and hi-temp painted)

Motolanna black cafe tail with no rear fender beneath.  Dry cell battery and ignition coil under seat.

Replacing casquette with Thunderbird yoke (puts bars right atop fork legs, lengthening the stance) and a sheet-aluminum minimalist dashboard with replica Smith speedo and maybe idiot lights.  

Black dirt track bars with moderate pullback, minimalist bar setup (no signals on this one...really clean bar with the original setup.)

Stock peg position for now, consider rearsets once it's ridable and I can see how they'll feel.  (Can fab or order locally for a LOT less than Hitchcock's...)

Taillight (the style that looks like the Lucas lamp with an erection beneath) tucked under the hump of the cafe tail on the support bracket for the seat.

Pull long shrouds off the fork, go with full or bottom-only fork boots.

Spot-sanding and touching up paint on frame and bodywork where necessary.

Will retain the toolboxes and against my usual thinking, both the case/leg guard and the giant front fender intact.  Gonna look weird on what's supposed to be a lean-and-mean bike, but both are practical here and they speak to the bike's heritage (and the fender numbers look awesome.) Might pull off the guard at some point and if I decide to bob the front, I will do it to a second spare fender I can find at the scrap heap.



Holy crap.  This is gonna be awesome!!



Title: Re: My New Plan
Post by: boggy on October 22, 2011, 07:21:39 pm
AgentX,
That military is sweet - I love the insignia.

I meant to post these for you back when you first mentioned your plans.  Maybe not the overall look for you but some pieces here and there for inspiration maybe.  These are the three bikes I've been looking at for the possible future of my Bullet.  Great for tearing up the city.

This is the Jack Pine Triumph from Hammarhead.
http://www.smithbutler.com/sb/wp-content/uploads/2011/03/jbikefinal.jpeg

This one is the Streetmaster Triumph:
http://www.bikeexif.com/custom-triumph

And the CRD Triumph Bonneville.
http://www.bikeexif.com/triumph-bonneville-9
Title: Re: My New Plan
Post by: barenekd on October 22, 2011, 07:28:28 pm
You can keep the casquette and use Ace bars to move the grips forward. Save you a lot of work on the front of the bike. that's the way I'm leaning on mine. Working on a putting together a minimal Clubman "S". Probably keep the stock tank and seat. I had a Norton Manx style cafe racer, miserably uncomfortable on a 200 mile ride. I want to maintain a bit more comfort this time.
Bare
Title: Re: My New Plan
Post by: boggy on October 22, 2011, 09:45:05 pm
These clubmans I have on have a 2" drop/2" pullback so they are pretty flat.  Took my wrists a few hundred miles to get used to them.  I love the riding position, even with standard foot positioning, but I'm not super tall at 5'8".

http://www.enfieldmotorcycles.com/forum/index.php?action=gallery;sa=view;id=3572

If you hit "next" you'll see the bars from the front.  I love the way they look.  I "may" go with a super bar setup next year, like the Triumph's I posted. 

I have a more typical set of ace bars that I'm not using.  I think its a 4" drop/4" pullback.  EMGO brand, which might be what the NField Ace Bars are since my NField Megaphone was also EMGO.  Think I bought'm for 40 or 50 bucks but I'd be willing to fire sale them if anyone is interested.
Title: Re: My New Plan
Post by: barenekd on October 22, 2011, 10:31:56 pm
Quote
I have a more typical set of ace bars that I'm not using.  I think its a 4" drop/4" pullback.

But will they clear the tank? I'm looking for something that will clear the stock tank. I don't want to have to put steering stops on the bike and end up with something that steers like a Ducati. Could we get a top view of the ones you have on there now?
Bare
Title: Re: My New Plan
Post by: boggy on October 23, 2011, 12:20:14 am
On the current setup the control switch housings will hit the tank, but my hand would make contact first preventing a ding.  It's not a problem at all. 

The NField site says their Ace bars are made to clear the tank.

Here is another pic of my bars that might give you a better look.

http://www.enfieldmotorcycles.com/forum/index.php?action=gallery;sa=view;id=3712

Title: Re: My New Plan
Post by: AgentX on October 23, 2011, 02:18:08 am
You can keep the casquette and use Ace bars to move the grips forward. Save you a lot of work on the front of the bike. that's the way I'm leaning on mine. Working on a putting together a minimal Clubman "S". Probably keep the stock tank and seat. I had a Norton Manx style cafe racer, miserably uncomfortable on a 200 mile ride. I want to maintain a bit more comfort this time.
Bare

Thanks-want to drop the casquette anyhow, just to achieve a more stripped-down look.  As a side benefit it'll let me use cool-looking pullback flat track bars.

When I get Stateside I think I'll go with clip-ons.

Definitely want to make it something distinctly different than it was when it served.  From solid workhorse to hot-rod toy in its retirement/renewal.
Title: Re: My New Plan
Post by: AgentX on October 23, 2011, 03:40:42 am
AgentX,
That military is sweet - I love the insignia.

I meant to post these for you back when you first mentioned your plans.  Maybe not the overall look for you but some pieces here and there for inspiration maybe.  These are the three bikes I've been looking at for the possible future of my Bullet.  Great for tearing up the city.

This is the Jack Pine Triumph from Hammarhead.
http://www.smithbutler.com/sb/wp-content/uploads/2011/03/jbikefinal.jpeg

This one is the Streetmaster Triumph:
http://www.bikeexif.com/custom-triumph

And the CRD Triumph Bonneville.
http://www.bikeexif.com/triumph-bonneville-9


I see your three and raise you one Johnson Motors Trophy:

(https://lh4.googleusercontent.com/-OkO9y7GqJGs/TXQt-EyTp6I/AAAAAAAABJo/yF5jJc06nEg/jomo-racing-trophy55_2.jpg)
Title: Re: My New Plan
Post by: Lwt Big Cheese on October 25, 2011, 11:12:08 am
AgentX: If it were me I'd get that bike re-built with new bearings etc and ride her as is. She is absoluty wonderfull.

Don't forget the more you change stuff the harder it will be to get it serviced/rebuilt on the trip.


But it's yours, do whatever you want with her...
Title: Re: My New Plan
Post by: AgentX on October 25, 2011, 11:34:35 am
Yeah, I'm not gonna go crazy on the engine at all.  Sticking with standard Indian-available stuff; engine-wise just gonna upgrade carb and exhaust, really. (Also not good to overstress something made to local tolerances!)

Aesthetically I'm going to do a lot of stripping-down, and I know that's not going to be to everyone's taste, especially on such a piece of history as this...but it's my bike, heh!  And I will keep everything totally reversible.  Only have one little tab/bar to weld on in order to get the new seat to fit, which will be easily removed should it be necessary (and I think the stock seat will fit on even after I've done this.)  Will use a removable bolt-on seat support, similar to what you can see in the Badger's build diary.

Once I get it back to the USA, though, it's Fireball time!  Whether I exchange the 350 engine for a 500 in a trade ,or try to replace the necessary parts on this one, time will tell.

Title: Re: My New Plan
Post by: Lwt Big Cheese on October 25, 2011, 11:38:19 am
Over here in the UK there is a conversion to take a 350 to 450 (I think). Apparently it makes for a fine bike.
Title: Re: My New Plan
Post by: AgentX on October 25, 2011, 06:22:32 pm
Just got my Snidal's manual.

Lesson one:  learn to fix the bike myself before trying to make it any significant amount faster, and if I'm going to mod it, focusing on reliability first before half-baked performance mods would be a good idea.

Still think I want the 5spd gearbox, though.  Crisper shifting is a nice thing at any point, and it'll serve the bike well as it grows to the Fireball it's destined to be.  A lot cheaper to get it over here than in the States, I'm sure.

Title: Re: My New Plan
Post by: AgentX on October 29, 2011, 12:21:19 pm
At the mechanic's; turned over all the parts today to begin a rebuild.

When I showed him pics of the cafe racer seat I was using and a stolen photo of a bolt-on mount someone else rigged up for this bike, he said, "Oh yeah, used to do that job a bunch a long time ago."  So score one for me and the mechanic; one less thing that's going to be a hassle.  Fabrication is super-cheap here.

(edited) Parts shop here didn't have the Thunderbird yokes to fit my fork but am ordering them from another domestic parts supplier.

Opted to use local parts for spark plug, ignition coil, and some other bits I was planning to use high-zoot stuff from the US for.  Just wanted to get work started/ done and these are easily replaced later.

Some better pics of the bike:

(http://i6.photobucket.com/albums/y218/MikesBikes/bike1-1-11.jpg)

(http://i6.photobucket.com/albums/y218/MikesBikes/bike1-1-10.jpg)

(http://i6.photobucket.com/albums/y218/MikesBikes/bike1-1-9.jpg)

(http://i6.photobucket.com/albums/y218/MikesBikes/bike1-1-7.jpg)

Jalani the mechanic and I:

(http://i6.photobucket.com/albums/y218/MikesBikes/bike1-1-5.jpg)

Buying parts; cost around $275 total for everything.  Still gotta get new shocks.  Looking around for a used 5-speed transmission because no one seems to know how to get a new one.  Will check with a dealer.

(http://i6.photobucket.com/albums/y218/MikesBikes/bike1-1-4.jpg)

(http://i6.photobucket.com/albums/y218/MikesBikes/bike1-1-3.jpg)
Title: Re: My New Plan
Post by: Lwt Big Cheese on October 31, 2011, 10:37:03 am
Oh man, your going to end up with yet another shiney Enfield. Just like everyone elses.   :-\

Sell her to me and I'll love her as she is!!!   ;D


Godd luck with it.
Title: Re: My New Plan
Post by: AgentX on October 31, 2011, 03:45:34 pm
Pretty much all that stuff is engine internals...guess you can see a decomp lever there but I have to replace the broken stuff.  Header has to be replaced, too, but I'm going to cover the shineyness with pipe wrap.  Don't feel like trying to find hi-temp paint to put over chrome.  Ugh.

While there will be some new parts on this thing (both by necessity and desire to change the design), overall it's still gonna look its age.  That's a priority of mine.

And I highly doubt ANYONE's going to have anything looking like this one when I'm through with it...   :)
Title: Re: My New Plan
Post by: AgentX on October 31, 2011, 03:53:17 pm
By the way, I found out I've gotta get rid of the tank's command insignia.  I sort of understand--as a former Marine infantryman I understand why some military things are sacred, although I'm long past caring myself what someone wears short of impersonation--but in this case I sort of feel the bike is the veteran and has earned its stripes.

So I'm thinking of just painting it over with a black disc (maybe with an olive drab number on it?), inventing some imaginary emblem to paint over top, or covering it with part of a Flying Tigers-style shark mouth.

Ideas?
Title: Re: My New Plan
Post by: bob bezin on October 31, 2011, 04:01:15 pm
keep the origonal tank. and get a used temp. tank  to use while over there . then eventually restore the bike.
Title: Re: My New Plan
Post by: RGT on October 31, 2011, 05:56:29 pm
agree with above, keep that tank as it is and run another one there, once back here you can reinstall that beauty...
Title: Re: My New Plan
Post by: AgentX on November 01, 2011, 01:38:57 am
Think I might just say screw it and ride it as-is, then see if it causes me trouble.  :)
Title: Re: My New Plan
Post by: RGT on November 01, 2011, 04:59:42 am
if you are there with dip status don't worry about it at all.
Title: Re: My New Plan
Post by: AgentX on November 02, 2011, 04:57:24 pm
Not that it applies to me, but even diplomats can be pulled over and cited for vehicle violations.  There's no mechanism to enforce payment or punishment afterward, but still--pain in the ass and if an embassy starts getting nastygrams about a scofflaw (for you Seinfeld fans) staff member they might come down on him internally for starting trouble.  Plus, there are varying levels of immunity.

Anyhow, I'll post more as the bike takes shape.  Hope too many people don't freak out that it's not going to look exactly like a traditional Bullet in some ways...
Title: Re: My New Plan
Post by: baird4444 on November 02, 2011, 05:13:54 pm


   Not like a Bullet??
what do you mean??
Why would you do that?
Title: Re: My New Plan
Post by: Lwt Big Cheese on November 03, 2011, 10:27:21 am
You don't need the decompressor on a 350 - well except to stop her!
Title: Re: My New Plan
Post by: Lwt Big Cheese on November 03, 2011, 10:57:58 am
AgentX: How much do fine looking army bikes go for over there?

Should I be looking for a holiday in India to get my next bike?
Title: Re: My New Plan
Post by: AgentX on November 03, 2011, 12:03:22 pm
I paid $1k for this one in non-running condition, after some bargaining and help from local friends.  A running-but-still-needs-a-rebuild 1973 was going for $1,250 or so.

If you're on vacation you might find the prices slightly higher as the "less inclined to walk away" and "foreigner" tariffs are super-steep.  And according to my friends they are getting harder and harder to find...I am lucky I did not  delay on snatching this one up when I could. (I also have no illusions; I did pay more than an Indian would have, and their encouragement likely had to do in some part to continuing business relationships they've established... "Hey, man, remember that time I got the American to pay $1k for that old army bike??!  Hook me up!!)

However, this is probably all very location-specific, too.  Dunno if we have more or less Army presence around here to furnish used bikes than other cities.

Baird, I am going to remove the casquette, use an integrated rear seat/fender cafe-style tail, might ditch the toolboxes, might use rear-sets depending on how the ergos work out, and was planning on bobbing the front fender quite significantly (although will NOT chop up the awesome one currently on there...will source a crappy old black one as a test model), so given the "keep it as is" sentiment running high with some people, I think I might be accused of blasphemy in the future.  

It'll look like a stripped-down hotrod of a Bullet, if my aim is true, but it's not going to be the classic snazzy-style 1950s British relic that many Bullet owners aim for.  Once in the States I'll go further with clip-ons and maybe an aluminum tank.  This might still look like a Bullet for some, but maybe not to others.

There was recently a whole thread on whether it was thinkable to remove the "face" of the Bullet by pulling the casquette...

Have to admit I love the bike as-is, too, but will sow my oats by tinkering with this incessantly.  Maybe I'll come around someday, in which case it's a few hours putting the salvagable original stuff back on, then I'm in business!

Of course, under all this superficial stuff I have to have a solid powerplant, but for now, I'm not doing anything too fancy with that.
Title: Re: My New Plan
Post by: Lwt Big Cheese on November 03, 2011, 12:49:05 pm
Thanks AgentX. One story I was reading had a guy employ a local to buy the bike. He reckoned he got the best deal that way.

It's a bit steeper than I thought. By keeping your ear to the ground bikes come up for that price here in the UK, occassionaly. No shipping or importing and registering required then either.
Title: Re: My New Plan
Post by: AgentX on November 03, 2011, 01:33:34 pm
According to the local buddies, a non-military bike might have been significantly less than that, had I been able to locate one of suitable age.

I had been looking for one which would qualify as classic under US import rules.  If I'd have been looking for an early 2000s-late 1990s IB model, it would have been much easier to find and much cheaper to buy.  Another foreign friend here paid a hair over $1k for his completely repainted, super-polished, very well-styled bike built (in an Indian way) to his specs.

Of course, he found that they'd cheaped out on almost every part they could in an effort to save money.  (Finishing work here is super-inexpensive so they went hog-wild on that...with good initial results that are now flaking off in spme places)  But they used second hand ignition coil and some other expendable parts which led to some significant frustration at first.

I am happy that the mechanic I chose is of a mind to use as many new parts in the engine rebuild as I'm willing to pay for and bring to him.  I have seen false economy at work in India and it ain't pretty.
Title: Re: My New Plan
Post by: AgentX on March 18, 2012, 07:13:11 am
So, STILL working on this here.  Long hiatus as my mechanic's son has serious medical problems; couldn't work for a month or three and I really didn't want to kick him while he was down by taking away work. Almost took the bike back just to give the engine rebuild a shot on my own, but now things are moving and hope to be ridable near the end of the month.

The paint situation has been a big disappointment, but it is what it is.  I was going to do some hand touching-up where necessary and leave the bike as-is as possible. But it was stored chained up outside the shop without wheels, with other stuff stacked near it, and it's taken a pretty bad beating and scratching on a number of parts.  Mad at the mechanic about that, but with the medical situation, I am trying to keep things in perspective.

And when I took it down to the frame, the condition on the tubes wasn't good.  So I opted for the total re-spray of all parts, especially since it'd look worse to my eye as a patchwork of new and old.  Since I just want a ridable bike, and I'm not committed to preservation of the bike for its own sake, I have accepted that I'll have to get the bike a second distinguished history in my hands.  Given my usual penchant for abuse, shouldn't take long. :)

The military repaints these things all the time themselves anyhow...the paint that' s on there actually isn't all that old, and in a way, I actually don't see how neglecting annual maintenance would honor its past.  Last thing I need is the ghost of an angry motorpool master sergeant haunting me.

And once it's re-sprayed, I'm going to go to the hand-painters who decorate the local lorries and get a special design hand-done on the tank.  Should still be pretty rad, and I won't have to deal with harassment from authorities over using a real unit's insignia.


Enough about paint, though.  Bike's going to have pretty much stock engine bits; will upgrade for performance as practical in the future.  Couldn't find an alloy 350 barrel locally but am still hunting this week before we close the engine back up.  Free-flow exhaust and K&N pod filter for now.  External spin-on oil filter.  Airbox of some sort in the future.  Maybe an electronic ignition.

Stock shocks front and rear, but will install the YSS cartridge emulators in the fork myself once I get the bike running.  Rears are the modern gas-charged units.  May upgrade them in the future to Hagon or Ikon or something.

Upgraded the wheels to full-width drums, 7" dual front and a 6" QD rear.  Not as stylish as the single-sided drums, but I want the best performance.  Might try mailing a set of shoes to the US be re-lined by Vintage Brake. Running K70s on both ends.

Stripping her down for weight and aesthetics as much as possible, as discussed earlier, but for now, will keep the toolboxes.  Need them for practical purposes, although I like the profile of the bike without them.

Anyhow, not much new to show, but progress is definitely being made now.  Hope to have some pics next week or so.
 

Edit:  Oh, yeah, have a set of Tarozzi universal rearsets which I will be running in a mid-set position.  Wanted something further back than the chair-like stock riding position, but still want to be able to post up on the pegs for crossing obstacles and keep my body relatively upright for the 360-degree awareness required in Indian traffic.  Getting mounts and linkages fabricated has been one of the bigger deals in the bike's genesis, since this is definitely not common to do on these bikes!
Title: Re: My New Plan
Post by: Blltrdr on March 18, 2012, 06:17:46 pm
I bought some Ferodo shoes from Vintage Brake a while back. They are a little on the high side but had a rare set in stock for my Yamaha. If you can't get the Ferodo linings or shoes (my #1 choice) you might check out Hitchcock's for an upgraded relined shoe set they offer for about 45 pounds. An upgrade to a disc brake would be more worthwhile in my opinion if you are setting your bike up as a cafe bike. I like the look of the drum brakes on my Bullet and understand there limitations and adjust my riding style accordingly. Drums are fine for stock or lightly modified Bullets but IMHO an upgrade to a front disc should be made if a full performance build is done to the bike or if you ride in heavy traffic where stopping on a dime is a necessity.

Good luck to you and your project. It looks like things are coming along nicely.

Brad
Title: Re: My New Plan
Post by: barenekd on March 18, 2012, 11:55:24 pm
I used to take my brake shoes to automotive brake shops and have them reline them with whatever they had in stock that they would consider great for a motorcycle. They did it while I waited. I never had any trouble with any of them and they stopped great. The point being is that you could probably send your shoes to a company like Ferodo and have them do it quite reasonably, if you can't find a local place. I haven't looked for a local brake shop since the '80s, so I don't know whether or not they even still exist.
Bare
Title: Re: My New Plan
Post by: AgentX on March 19, 2012, 04:13:10 am
I bought some Ferodo shoes from Vintage Brake a while back. They are a little on the high side but had a rare set in stock for my Yamaha. If you can't get the Ferodo linings or shoes (my #1 choice) you might check out Hitchcock's for an upgraded relined shoe set they offer for about 45 pounds. An upgrade to a disc brake would be more worthwhile in my opinion if you are setting your bike up as a cafe bike. I like the look of the drum brakes on my Bullet and understand there limitations and adjust my riding style accordingly. Drums are fine for stock or lightly modified Bullets but IMHO an upgrade to a front disc should be made if a full performance build is done to the bike or if you ride in heavy traffic where stopping on a dime is a necessity.

Good luck to you and your project. It looks like things are coming along nicely.

Brad

Does Vintage Brake have the Enfield shoes as stock?  I thought I'd have to send them a set to be re-lined...  (Edit:  Disregard; I fail reading comprehension for today.  Yamaha. Right.)

I was planning on the upgrade but wanted to see what stock was like so I'd understand the improvement... :)  I have the disc on my current bike, so I am already a bit spoiled...although I think even the disc setup lacks power and good feel compared to many other makes.

I will consider the disc upgrade for sure if I end up getting new fork lowers at some point.  And/or do a total front-end swap once the bike is back in the US, for a stiffer fork with a good disc setup.

For now, the bike's only a 350, will be lighter than stock, and traffic here is slow, but I am a firm believer in only going as fast as you can stop.  Well-tuned drums, I'd hope, would do me right.  On the other hand, I believe in braking late and braking hard, which is going to get me an autorickshaw up the ass sooner rather than later...maybe I should stick with less powerful brakes for my own good?
Title: Re: My New Plan
Post by: Lwt Big Cheese on March 19, 2012, 08:58:06 am
I've been wondering how you'd got on with your mods.

Thanks fot the update.

Now we need more pics!
Title: Re: My New Plan
Post by: AgentX on April 25, 2012, 05:06:25 pm
omgomgomgomg!

I am still super-pissed at the mechanic for continual runarounds and disappointments.  However, I am now doing a little secret dance of joy in my heart.

The bike is pretty much together.  Engine's starting, sounds nice...snarly and a little less mellow-thumpy due to the silencer choice.  The toughest bits of chassis work are still ahead...seat mounting and final positioning/linking of the pegs.  (Mid-set, on little brackets coming off the passenger peg mounts.) 

And manomanoman.  I was really having nightmares it'd come together as a lumpy mass of Frankenbikeish proportions, since I did a lot of speculating and SWAGing and dreaming as to how it'd all look together.  But it looks AWESOME.  Just awesome.  Not precisely how I'd envisioned, owing to practicalities and realities.  And in some ways better than I'd envisioned.  Quite the little street-tracker, it is.  Front end is pretty clean and minimalist, tail section is short and light.  Looks good with the toolboxes on, and I'll probably keep them for the time being.

Alas, I did not have the camera with me tonight.  Sad, because the partially-assembled bike against the background of a riotous Rajasthani wedding procession would have been an awesome visual.  But I'd just come from work and wasn't thinking.

Should maybe be ridable on Saturday.  We'll see.

I will have some work to do on my own once it's in my hands.  Probably have a new seat bracket fabricated, as the mechanic is trying some wonky-ass way that he insists will work and I'm really tired of arguing with him...I just want this thing in my hands so I can get it done right.  Gotta install the fork cartridge valve emulators, probably moving the ignition coil up under the seat, maybe clean up the wiring and swap out some switchgear.  Still looking for a 5-speed transmission and an alloy barrel.  Might send some brake shoes over to Vintage Brake for re-lining with super-duper stoppy stuff.



Maybe I'll buy another and build a bobber next, this time in my own front yard.  :)
Title: Re: My New Plan
Post by: Lwt Big Cheese on April 26, 2012, 07:34:15 am
Quote
Should maybe be ridable photographable on Saturday.  We'll see.


 ;)
Title: Re: My New Plan
Post by: AgentX on April 26, 2012, 12:20:50 pm
Hah.  Hope so.  This thread is literally worthless without pics, and is just a lot of useless blathering to this point.  I'm surprised there's even one person still tuning in.

But the only pics I've had since the initial round are a set of the frame, then the frame and partly-assembled engine with the new triple trees.  I'll put them up for a laugh when I get home tonight.

Won't be forgetting the digi camera on Saturday, that's for sure.  I'll probably be bringing the Leica or the Rollei, too.


Title: Re: My New Plan
Post by: Desi Bike on April 27, 2012, 03:33:41 pm
Quote from: AgentX link=topic=12334.msg150956#msg150956

Won't be forgetting the digi camera on Saturday, that's for sure.  I'll probably be bringing the Leica or the Rollei, too.




I like your taste in camera equipment and look forward to your pictures.
Title: Re: My New Plan
Post by: AgentX on April 28, 2012, 06:06:31 am
Teasers as promised 2 days ago...

bike should be done today.  (Hah.)

(http://i6.photobucket.com/albums/y218/MikesBikes/IMG_2204.jpg)

(http://i6.photobucket.com/albums/y218/MikesBikes/IMG_2256.jpg)

(http://i6.photobucket.com/albums/y218/MikesBikes/IMG_2254.jpg)
Title: Re: My New Plan
Post by: Lwt Big Cheese on April 28, 2012, 07:35:28 am
Thanks for the pics.

Looking good.

Whilst the bike is tantalising, I love the pic with the street  in the background. I can only imagine what it's like going out there into the bright, hot sun - and all the smells. Spain on steroids?
Title: Re: My New Plan
Post by: AgentX on April 28, 2012, 08:31:04 am
Spain has got NOTHING on India.

Some other digi snaps from around the shop--it is in a rather picturesque part of Old City here.

(http://i6.photobucket.com/albums/y218/MikesBikes/jelanis-1.jpg)

Jelani's highly organized methodology contributed to the timely completion of the bike, I'm sure...

(http://i6.photobucket.com/albums/y218/MikesBikes/jelanis-1-4.jpg)

(http://i6.photobucket.com/albums/y218/MikesBikes/jelanis-1-5.jpg)

Beginning of a religious procession used to foment nationalist/communal violence in the following few days...there were many attempts by the drunk and high dancers to drag me bodily into the mix. 

(http://i6.photobucket.com/albums/y218/MikesBikes/jelanis-1-2.jpg)

Old Yezdi (2-stroke funky thing, very popular with some in India as a classic alternative to Enfield)

(http://i6.photobucket.com/albums/y218/MikesBikes/jelanis-1-3.jpg)

Someone's always parked just across the street.


(All photos straight from the digicam and not intended as an exhibit of photographic skill or editing... for informational purposes only!)

Title: Re: My New Plan
Post by: AgentX on April 28, 2012, 03:11:36 pm
Should I start a new thread with pics of the bike?  I think a lot of people might be more interested in the baby than in the 3-page mass of labor pains that is this thread.

Not that it's actually done, but still...
Title: Re: My New Plan
Post by: GreenMachine on April 28, 2012, 04:28:54 pm
AgentX - love the pics..Brings back lots of memories...So the color is like a gray/greenish military color...Its looking great being put to together on the sidewalk...Lots of assembly work done that way especially in old Delhi..Hey I thought I saw that old tire I threw out in that mishmash pile.....Looks like u having lots of fun...Keep up the pics and can't wait to see the finished running product...I'm assuming u going to bring it back with you or to your onward assignment or in storage?...
Title: Re: My New Plan
Post by: AgentX on April 28, 2012, 04:58:17 pm
That's the idea.  As a 1977 it should be importable to US without restriction.  Plan is to swap for clip-ons and fully rear-set the pegs, then Fireball it.  (Either modding the cases to accept a 500 barrel/head or just trading the 350 for a 500.)

Just started a new thread with pics of it built(ish).  Figured more people'd be interested in a "hey, look at the bike!" thread than this ramble...

Title: Re: My New Plan
Post by: Okie Enfield on April 28, 2012, 10:40:21 pm
Those pics are awesome!..........
Title: Re: My New Plan
Post by: AgentX on July 21, 2012, 06:55:32 pm
(Now an older pic but not much has changed except the shocks and some license plates...)
(http://www.enfieldmotorcycles.com/forum/gallery/3646_03_05_12_12_27_41.jpg)


After a long battle, it's now set up with an alloy barrel and a 5-spd right-shift transmission, and working through the break-in.  Slapped adjustable Hagons on there, too.

And it got a few treats today...

-Got a proper linkage rigged up on my rearset to replace the flipped-backwards shifter I'd been running; was too short and not shifting well for a few reasons.  Looks more professional than anything else on the bike and shifts amazingly.  I lost the one-up-four-down pattern I wanted to run, but am just happy I can ride it without a problem now.

-Adjusted my points gap, which fixed a bunch of problems I was attributing to an overly rich pilot jet.  Still gotta re-jet but the bike is behaving much better in the meantime.

-Opened my primary to seek the source of a bit of occasional disconcerting noise and grinding sensation.  Found the chain adjuster had slipped, and the primary was running too slack.  Then noticed that the chain adjuster has a provision for an underside adjuster bolt...my previous "mechanic" had not used one and the adjuster was collapsed to the slackest position.  Got a bicycle chainring bolt from my parts box and voila, I'm no longer having nightmares about my alternator or clutch detonating.

-Sanded and hand-painted (ie, poorly) a chrome exhaust strut to match the green frame.

Still need to:

-Obtain new fork sliders and install my cartridge emulator valves

-Re-jet the pilot

-Seal up the reducers between my muffler and header, which allow some exhaust to puff out.

-Re-locate rearsets to a more mid-set position.  Could be difficult based in where I wanna have them.  Don't want to weld tabs on the frame so maybe I'll just leave as-is...this is why the guy who was supposed to mid-set them put them where they are in the first place!

-Change my contact breaker unit, as this one just seems to have seen better days.  All the fixing nuts are chewed up beyond usefulness and the points look a bit ground down.

-Rig up a shorter rear brake actuating arm to help scale it down to work better; the rearset "arm" isn't as tall as the stock brake lever.  Should be able to cut off the forked adjuster barrel end, drill a 6mm hole in the stub of the actuator, and run a rod with quick-disconnect clevis ends on both sides to tie it all together.

-Receive, paint, and install new swingarm...this one seems a bit twisted to the left, and the fork ends were seemingly partially ground out by someone at some point for some unknown reason.

-Try to find an inner chaincase that will let me mount my stator directly to it...the arrangement in the current one uses a sort of adapter ring which is torture to deal with.  When you bolt the stator to the ring, it precludes access to the cap screws that fix the adapter to the chaincase.  But if you fix the ring to the chaincase first, you can no longer access one of the bolt heads which attaches the stator to the ring!

-Go to a high-quality plug and coil

-Try in earnest to mount a plastic tire licker for use in the monsoon season.

-Eventually, re-wire this whole sucker.  Everything was set up by the "mechanic" in Indian fashion...wires twisted together, no solder or positive connections, everything in a real rat's nest.  I do have the deluxe package, though...lots of electrical tape covering it all!

-While I'm at that, obtain a tail light with brake light capacity and rig up the switch in the tool box.

-Decide, eventually, if I want to keep the cafe/tracker tail or go with a more vintage flat-tracker look using a fender and solo seat.  If I keep the tail section I'm gonna look at a more elegant mounting solution.
Title: Re: My New Plan
Post by: Arizoni on July 21, 2012, 11:42:20 pm
I've heard that owning a Royal Enfield Bullet can give the owner something to do with his spare time.

Rather than just sitting there on your butt, you really need to start thinking about some projects for you to do to the bike.
Something that might make the bike run a little better or perhaps, be a little more dependable.

I'm sure you could find something.


(Boo-ha-ha-ha-ha.  Hee-hee-hee.)  ;D :D ;)
Title: Re: My New Plan
Post by: AgentX on July 22, 2012, 04:21:22 am
I've heard that owning a Royal Enfield Bullet can give the owner something to do with his spare time.

Rather than just sitting there on your butt, you really need to start thinking about some projects for you to do to the bike.
Something that might make the bike run a little better or perhaps, be a little more dependable.

I'm sure you could find something.


(Boo-ha-ha-ha-ha.  Hee-hee-hee.)  ;D :D ;)

yuup.  I forgot that I adjusted the valves yesterday too...
Title: Re: My New Plan
Post by: AgentX on September 19, 2012, 01:47:02 pm
Made the first long ride today.  Hit 70mph briefly, even.  (An optimistic speedo 70...should try with GPS.)

I am smitten with the bike now.  It's been agonizing, and still is, but truly fun and rewarding.  Miles to go, still, to get it perfect, but one step at a time.

Will put up something in ride reports when I get more pix from my buddy.

(http://i6.photobucket.com/albums/y218/MikesBikes/Riding/IMG_3051_zpsa7797ed1.jpg)
Title: Re: My New Plan
Post by: ace.cafe on September 19, 2012, 02:19:22 pm
Looks nice!
Glad that you got the mixture sorted better. 70mph is pretty good for a 350.

Once you get smitten by the Bullet, it never goes away. It's pretty much unique, even among Brit singles. It has a "certain something".

Title: Re: My New Plan
Post by: boggy on September 20, 2012, 03:23:21 am
Hey, looks great AX!
Has a really great stance to it.  Like how open it looks.  Seems like you had to make some custom welds to get that straight seat over the electronics?  Fenderless rear looks awesome... makes it look tough.  Rear tool-boxes set it apart from any other tracker.  As I've mentioned before, love the sans-nacelle look.  Shiny pipe looks good too against all the drab.

Looks kick ass man.  Nice work.
Boggy
Title: Re: My New Plan
Post by: AgentX on September 21, 2012, 05:03:17 pm
Thanks, gents.

Ace, the mix is still a work in progress, but I am learning.

Boggy, the seat sub-frame is simply a piece of angle iron cut/bent/welded into a cross-brace of appropriate height that bolts onto the eyelets in the frame.  It has struts to the rear shock mounts to stabilize it, and a strip of bent metal at the top which engages the interior curve of the seat hump.  Seat has threaded mounting holes built in, so it's just bolted onto the frame.  Incredibly crude but seems effective.  Front of the seat has prongs (unit is designed for an old Yamaha) which engage a small metal "t" welded just aft of the tank.

I do like the stance of the bike--am using slightly longer shocks to tighten up the angles and raise it a bit.

Bike still has the interior fender in back which protects the engine et. al. from spray, but I am going to get a small alloy fender-tip thing made up to follow the curve of the back of the seat hump.  Really needs a bit more mud-catching ability; I have a permanent skunk-stripe of road gunk and mud on my jacket.   Just need a little more length on the back, and this should maintain and even improve the look.  Tail light will be a small lucas-style one just on the underside of the fender tip

Next step is a disc brake up front!  I really didn't want to go there, but I wanted to replace my fork sliders.  The oil seal threads are shot and I can't find a good way to repair them, and the only genuine RE option available new is the disc fork.  (Tired of mucking around with aftermarket and crapped-out used junk.)  Damned cheap here so I might as well do it.  I am almost tempted to buy some nice alloy rims to go along with the disc conversion, but don't know if I can bring myself to spend the cash right now.

Also have some electrical upgrades to do.  NField gear had an up-rated alternator for sale and I scored a Boyer Powerbox cheap.  Bosch coil also on its way.

Installed a new swingarm today, but it doesn't seem to have fixed the bike's alignment problem.  Maybe it lies in the QD drive unit I am using (retro-fitted to the 1977) or the whole frame is misaligned.  If so I guess I'll live with it until I'm back in the States and the bike gets a full tear-down...then maybe a specialist could re-align it, right?

Am guessing it's the QD, though, since it seems to be a problem with the axle itself being not square to the rest of the frame.  Didn't notice anything which seemed to be off in the framewhen swapping the swingarm itself.

Got a minor primary leak now which is annoying me.  Cleaned the rubber ring seal but it's still seeping.  Maybe from the back, I am guessing.

Title: Re: My New Plan
Post by: Ducati Scotty on November 03, 2012, 05:16:30 am
X, I'm thinking about mounting the same rearsets to my UCE C5, and I'm shooting for a middle position as well.  Could you post some close up pics of what you have now just so I can see?  I'm gathering/fabricating parts to mount them.  I'll be sure to share whatever I put together with you.  I think it will actually be a pretty simple thing to copy once it's all done.

Scotte
Title: Re: My New Plan
Post by: AgentX on November 03, 2012, 07:17:09 am
Closest thing I have to a decent pic at the moment is this:

(http://i6.photobucket.com/albums/y218/MikesBikes/IMG_2357.jpg)

1) mount is a cylinder (slightly cone-shaped, I surmise, to wedge in solidly as the bolt tightens) bolted through the passenger peg mount.  Welded to the cylinder is a tab coming forward, which gives adequate clearance from the frame and gets them forward of the toolboxes.  This was fabbed by the mechanic who did the original assembly on the bike and I haven't messed with it, so I'm not really sure exactly how it looks when disassembled from the frame.  The method seems kinda sketchy in theory but has been rock-solid so far.  You can see he drilled out an adjustable positive stop for the actuator, as well.  I'm no longer using this.

2) The brake rod shown here came off a small Japanese or Indian bike.  It incorporates a spring arrangement to deal with rearward motion of the actuator arm when the bike bounces.  I'm not using it anymore; switched to the standard threaded-rod-inside-aluminum-tube actuator that most oldschool-style rearsets are using, but am having real trouble with the clearance of the brake arm around the mounting bolt.  (see how it's bent here?)  Might order a bent linkage rod from fastfromthepast or something.

3)  leverage: you get a lot less leverage from the shorter lever-end actuator compared to the standard brake.  And if you leave the drum actuator at its stock length, you have decent power but have to push the lever way too far to get it, IMHO.  So I shortened the brake drum actuator as well, to preserve similar ratios to stock...will have to show a pic to explain exactly what I did.  Now my power is kind of pathetic but the travel is short and feel is firm.  Still working on getting this right.

4)  Folding:  You really want folding pegs for purposes of kickstarter clearance

There's a company in India selling rearsets with mounting brackets (and a whole cafe body kit, kinda aesthetically clumsy IMHO) ready-made. Know nothing about them but you could try them--  Sans classic, inc.

All in all, this peg positioning is further back than I wanted for a street-tracker but less aggressive than I'd want for a cafe racer.  Does the job, though, and I have enough other stuff to mess with right now.

Ideally, for a mid-set, I'd want the peg to be concentric with the brake arm mounting boss on the frame, just under the swingarm pivot on the left-hand side.  Right side has nothing on there, though.

Welding tabs on would be the simplest mounting method, welding aside, but there are enough tabs on there already that you could get someone to cut a sheet-steel bracket out somehow that would bolt to some existing bosses on the frame and give you a peg mounting surface exactly where you want.
Title: Re: My New Plan
Post by: Ducati Scotty on November 03, 2012, 08:09:28 am
Thanks for the pic.  I have the same concerns about the leverage on the rear brake.  I figure I'll need to move the mount point on the rear lever like you did.  My brake is on the right so I need to worry about clearance above the exhaust pipe for the pedal too.

I'm hoping to be able to position mounting plates for the rearsets between the swingarm pivot and the rear lower engine mount bolts.  I'm guessing you have similar mount points on your frame so you ma be able to do the same.

Scott
Title: Re: My New Plan
Post by: ace.cafe on November 03, 2012, 12:02:32 pm
That rearset control looks like a Tarozzi two-piece.
Can you just move that chrome lever part to the outer face of the rearset foot control, for more clearance from the frame.
Does it have to be on the inside face of the foot lever?
Title: Re: My New Plan
Post by: AgentX on November 03, 2012, 03:06:21 pm
That rearset control looks like a Tarozzi two-piece.
Can you just move that chrome lever part to the outer face of the rearset foot control, for more clearance from the frame.
Does it have to be on the inside face of the foot lever?

Yep, it's a Tarozzi.  The actuator lever must be where it is...it's held in place by a pin locator (adjustable orientation) and the screw-down innermost ring.  Slightly offset versions are available, though.
Title: Re: My New Plan
Post by: barenekd on November 03, 2012, 06:58:37 pm
With my upswept pipe, the brake rod runs inside the muffler and the muffler is canted out slightly to clear it. The exhaust pipe itself is pushed farther under the engine case to better keep my leg off it! But everything is cleared nicely.
My setup is the Indian one and appears to have longer arms for the brake and shifting rods. The rear brake works as well as I like a rear brake too work. I can lock it up if I really want to, but I'd usually rather not. It has a short throw, about the same as the stock setup. The kit comes with a shifting arm that is the same length as the actuating arm at the peg, so the shifting throw is about the same as stock.
Bare
Title: Re: My New Plan
Post by: Ducati Scotty on November 03, 2012, 10:28:38 pm
X, any chance you could give me these dimensions off the Tarozzi rearsests?

(http://www.enfieldmotorcycles.com/forum/gallery/2695-031112172540.jpeg)

Thanks,
Scott
Title: Re: My New Plan
Post by: Ducati Scotty on November 03, 2012, 11:30:03 pm
Never mind, got 'em.

Scott
Title: Re: My New Plan
Post by: AgentX on November 12, 2012, 10:12:45 am
It's allliiiiiivvvveee!

Finally got it back on the road with all new wiring, Boyer Powerbox, new Bosch ignition coil and a solid alternator in a properly-drilled primary case.  HID headlight, too.

I'd been having a problem while trying to replace the alternator, in that the (aftermarket) inner primary case was mis-drilled somehow and just wouldn't allow the stator to mount in the proper place.  (as in, there simply wasn't enough movement so that the rotor could run without contact, not that I don't know how to space the stator and rotor.) 

Then when putting the alternator on, I found the wiring on the bike was such an incoherent black-taped spiderweb of a mess I just had to trash it and try my hand at rebuilding it myself.  Since the bike's not very standard in configuration, the factory harness wasn't very applicable.  Big learning curve, but now it's in, the wiring is clean (except behind the headlight, where I really mis-judged things), and the battery, coil and rect/reg are tucked under the seat.

It's so gratifying to see the ammeter in the positive, finally, even with the headlight on.

Still have some kind of mix/timing thing to work out, though.  But it moves again...that's something.

Now to get to that front-end swap for the disc brake fork...having a real problem getting the top caps of the stanchion tubes.  Went to the local shop who informed me they just clamp them in vice and beat down on a big crescent wrench to get them off...they figure customers will never notice the marking and possible ovalization of the tubes because they do it where it's covered by the casquette.   :o

Apparently another shop may have an appropriate impact tool to do it right.  I can't make any headway doing it by hand.

Oh, and I should be getting some better rear braking and shifting soon, courtesy of solid linkage rods with appropriate bends to get things spaced out just right.
Title: Re: My New Plan
Post by: Afro Samurai on November 14, 2012, 04:21:00 pm
You running same tires on front and rear?...look like same width...

Those dunlop k70?..81?...
Title: Re: My New Plan
Post by: AgentX on November 15, 2012, 04:38:27 am
K70, 3.5 front and rear.  The slightly bigger rubber up front doesn't seem to be a bad thing given local conditions.  Lots of chunky pavement and dirt, not too much high-speed handling or sweeping turns.  It's only 1/4" over stock anyhow; even on my mountain bike, that minimal difference in tire width is fairly insignificant.

Anyhow, it turns in just fine.  With my slightly longer rear shocks, the tighter steering head angle keeps things frisky.
Title: Re: My New Plan
Post by: Mike_D on November 25, 2012, 12:45:44 pm
AgentX just read the whole thread.  Great bike!  I spent a considerable time in India with an Enfield - rode over 8000km - and this post brought back some good memories.  A Yezdi!  I remember spotting a few of those but never saw one in running condition.....
Title: Re: My New Plan
Post by: AgentX on November 25, 2012, 01:31:05 pm
AgentX just read the whole thread.  Great bike!  I spent a considerable time in India with an Enfield - rode over 8000km - and this post brought back some good memories.  A Yezdi!  I remember spotting a few of those but never saw one in running condition.....

Thanks--just took it on a long group ride today. 

I think I've sorted many of the issues and was pretty pleased with its performance.  It gets an annoying amount of attention, but hey, it's generally positive.  (Although the constant requests to buy it--for 50,000 rupees or less, even--and demands to know "how much cost this" and "where do I get this bike?" are a litte tiresome.)  Been here over 2 years now, less than a year to go...happy to have done the India thing but not at all upset to be moving on to something new.

Got any pics from your own India riding??  We've got quite a few nice running Yezdis and Jawas around the city.

MD
Title: Re: My New Plan
Post by: RGT on December 17, 2012, 07:00:34 pm
Great project
Title: Re: My New Plan
Post by: GlennF on December 18, 2012, 02:39:29 am
I noticed you are talking about changing the 350 barrel and piston for the 500 ones at a later date.

This may not be a good plan. My understanding is the lightweight 350 crank means the bike will rev much better than a normal 500 but it also will vibrate and shake very badly.
Title: Re: My New Plan
Post by: AgentX on December 18, 2012, 05:23:39 am
Some have used the 350 crank successfully, but there's also a "heavy" 350 crank which is apparently just a 500 crank.

In any case (groan) I have located a 500 bottom end I'll be using.  This is cool; I can keep my 350 as a spare engine and build the 500 up as a Fireball.  Registration of the non-matching numbers will hopefully not be too much of a problem.
Title: Re: My New Plan
Post by: RGT on December 18, 2012, 04:21:34 pm
 you will not regret the fireball 535 upgrade. I built up a 2nd motor when I did mine, though mine had new replacement cases without numbers, I up selling the bike with the 350 back in it, looking for a donor 5 spd bike now, or maybe I will find another head and barrel and go twin Fireball....
Title: Re: My New Plan
Post by: GlennF on December 19, 2012, 05:09:08 am
There are of course also long stroke 570 cranks about.
Title: Re: My New Plan
Post by: GreenMachine on December 19, 2012, 02:32:26 pm
agent x: Registration of the non-matching numbers will hopefully not be too much of a problem on.

Is it a done deal re. shipping the 350 enfield in your HHE back to conus, storage or to your onward assignment.....Things have a way of changing at the last minute over there re. who said what and the interpretation of regulations...Hate to c u go through all this effort just to see u have to leave it there with a friend with the hopes of getting something out of it....GSO should be able to tell u specifics/Hopefully...GM
Title: Re: My New Plan
Post by: AgentX on December 19, 2012, 02:54:33 pm
Export's no big deal.  Just need a local "no objection" certificate.  Import is easy since it's older than 25 years and qualifies as a classic.  Someone else just did the same thing...  (inspired by me, of course, but they left here first.  :) )Next position will be without family so it'll stay with them in the US.

The non-matching numbers won't be an issue until it's in the US.  It's being exported/imported with the original engine in it.  Won't have my Fireball to install until I'm back in the States anyway.
Title: Re: My New Plan
Post by: GreenMachine on December 19, 2012, 03:20:44 pm
sounds like u got it covered...GM
Title: Re: My New Plan
Post by: AgentX on December 20, 2012, 07:05:26 am
There are of course also long stroke 570 cranks about.

Not too interested in increasing the stroke, honestly.
Title: Re: My New Plan
Post by: noisymilk on December 21, 2012, 06:13:41 pm
Just popping in here to say how cool your project has turned out AgentX.

Well done, and good luck with importing.

I may have missed this in the thread, but when are you moving back stateside?
Title: Re: My New Plan
Post by: AgentX on January 01, 2013, 01:01:03 am
Thanks Milk--

Still have miles to go before I sleep, but overall it's been a great learning experience.  Think I've got the plan for the new engine in place and am looking forward to a little more reliability as much as I'm looking forward to performance.

That front end-swap should be happening in the next week or three.

Appreciate the kind words.  I'll be back Stateside late next summer, but will be heading out again for another year after a few months of leave and training.  (Going someplace hot and dusty for a short tour...)  Hope I can get the new build together over those months and maybe while I'm back on a few R&R trips over the following year.

No idea where I'll be after that; with my luck it'll be somewhere that won't let me import a 37 year old motorcycle from India...  :)
Title: Re: My New Plan
Post by: Arizoni on January 01, 2013, 04:29:09 am
Well, I hope you land in a place where they would be happy to see your bike imported.

Wishing you and everyone else on the forum a Happy New Year with many good rides. :)
Title: Re: My New Plan
Post by: Ducati Scotty on January 02, 2013, 03:50:57 am
So while I was looking into different foot control options I ran across Kuryakyn.  They make lots of different styles, mostly for cruisers and Harleys but they have a cool system that could be adapted.

Their system is composed of a clevis that mounts to the frame, a post that mounts to the clevis, and a footpeg that mounts on the post.  The clevises come in a few different lengths and there are also extensions.  Combining different parts you can get lots of different lengths, so once you find your mounting point and determine how far out you need to come, just mix and match to get what you need.  They also have replaceable rubber bits to absorb the vibes which is nice for bikes like ours.

Here are some links to the footpegs with dimensions and some of the clevises and extensions:
http://www.kuryakyn.com/files/general/Footpegs%20for%20web_Harley.pdf
http://www.kuryakyn.com/Products/493/Footpeg-Mounts-Mounting-Clevises
http://www.kuryakyn.com/Products/559/Male-Mount-Footpeg-Extensions

You'll still need to fab up the shift and brake controls if you use these.

Scott
 
Title: Re: My New Plan
Post by: AgentX on February 09, 2013, 03:47:52 pm
Oy, vey.  Been a doozy of a few weeks with the bike sitting forkless in the driveway on a jack.  Thought I had everything set for the fork swap for a disc setup.  New pumping rods drilled and springs cut to fit the valve emulators, everything painted, new top crown...yadda yadda.

Then it turned out nothing fit (imperial/metric issues, but a few other compatibility issues) and it took a few weeks of running around to get all the hardware that meshed.  Worst part was my valve emulators from the old fork won't fit the new one--the new stanchion tubes are just a bit thicker.  That meant my cut springs and drilled pumping rods were also useless, so I had to get new un-cut ones...the agony continues.

While the bike was down, I pulled the distributor shaft which had frozen stuck to the timing advance unit and replaced the points cam, which was a non-factory bodge with a strange profile, and which didn't run true.  Bonus...I think I may be able to keep set bike for a steady idle now.

Worst part was the bar clamp on the Thunderbird triple tree--it's some bizarre thread; still don't know what it's supposed to take.  No dealer couldn't help and kept trying to foist 1/4-20 studs on me, which do fit every other top crown in the world, but apparently not this one.  Alternator studs, strangely enough, seemed to fit but a bit loose, and I ended up with a stripped-out clamp.  Which is fine--I kinda needed to have them re-tapped for a more available thread anyhow.  But it did make my triumphal ride pretty ginger, since I had the bar clamped down properly on only one side.  It was also short, since I needed to remove the top crown again to get it fixed.

It was kind of soul-crushing to have to take off the bars, the dashboard, etc. to get the top crown back off and leave the fork just hanging there, but I'm not going to half-ass the machine work by trying to do it with a hand drill in situ; plus, I think it might be best to fill the existing holes with weld and re-drill/tap.

Next up, maybe a new custom tail section with electrics undertray, and re-re-wire job now that I know how to do it better, along with some other possible doodads.

Fireball is going to be in the works Stateside as soon as I can get the engine parts to Ace and Chumma...hope the shipper can put them in the mail soon.

[/soliloquy...for now.]

Title: Re: My New Plan
Post by: AgentX on May 19, 2013, 01:06:22 pm
Aaaaand..."nes-cafe."  (ie, instant.  Just add clip-ons!)

I think I'll be going back to tracker bars, honestly.

Electronic ignition installed.  KrankVent to arrive next week.  Got a big tach and mini speedo to mount up, but that will probably wait until the big re-wiring.

I have an alloy seat unit to polish up and mount; might get that done here, might not.  Will have an electrics tray underneath to hide and protect everything.  Might powder or hard-anodize black if I don't like the shiny alloy after some time to adjust.

Rebuilt bike in the US will have alloy rims and some other shiny goodies...it'll be a less-drab version of what I have now but retain the military cues.

It's running reasonably well at the moment, thanks to the electronic ignition, but the head/barrel really need to be machined to mate better. No point in doing that now.  2 more months and I'm out of here and once the bike gets to the US, it'll be stripped to the frame to await the new Fireball engine.



(http://i6.photobucket.com/albums/y218/MikesBikes/DSC_0037_zps7e23384e.jpg)

(http://i6.photobucket.com/albums/y218/MikesBikes/DSC_0042_zps7f50528b.jpg)
Title: Re: My New Plan
Post by: RGT on May 19, 2013, 01:35:16 pm
looks great, I hope you and your bike make it back in good shape.
 I shipped my Fireball engine back to the states last week and I should be putting that in my new '04 that I have waiting for me(it has a blown engine) in July or August while home...
Title: Re: My New Plan
Post by: ace.cafe on May 19, 2013, 02:17:03 pm
I'd recommend putting a wrap of protective screening around the front of that oil filter element.
It's right behind the front wheel, and stones could kick up and puncture the filter element.
I cut a square section out of an old screen door that had a heavier mesh in front of the bug screen, and then used zip-ties to wrap it tight to the filter element on mine. Also, I offset my filter housing toward the primary side, so it wouldn't be directly behind the wheel.
Title: Re: My New Plan
Post by: AgentX on May 19, 2013, 03:05:48 pm
I'd recommend putting a wrap of protective screening around the front of that oil filter element.
It's right behind the front wheel, and stones could kick up and puncture the filter element.
I cut a square section out of an old screen door that had a heavier mesh in front of the bug screen, and then used zip-ties to wrap it tight to the filter element on mine. Also, I offset my filter housing toward the primary side, so it wouldn't be directly behind the wheel.

Thanks--on planning for the fireball, I was going to re-mount it vertically on the frame down tube to keep it well clear of the road.  Any disadvantages in that?
Title: Re: My New Plan
Post by: Chuck D on May 19, 2013, 03:11:45 pm
Your bike looks really great! best of luck in getting it home.
Chuck.
Title: Re: My New Plan
Post by: ace.cafe on May 19, 2013, 03:35:39 pm
Thanks--on planning for the fireball, I was going to re-mount it vertically on the frame down tube to keep it well clear of the road.  Any disadvantages in that?

As far as I can envision it, that would be fine. I don't see problems with vertical mounting unless it's upside down, in which case the filter element would need to be equipped with an anti-drainback valve to prevent filter drainback.
Title: Re: My New Plan
Post by: AgentX on May 19, 2013, 03:49:36 pm
As far as I can envision it, that would be fine. I don't see problems with vertical mounting unless it's upside down, in which case the filter element would need to be equipped with an anti-drainback valve to prevent filter drainback.

Nah, it'll be right-side up, probably just held with a u-bolt or something.  Will work it out with Chumma.

Thanks!
Title: Re: My New Plan
Post by: Ducati Scotty on June 06, 2013, 10:29:02 pm
Looks really nice!
Title: Re: My New Plan
Post by: AgentX on June 08, 2013, 06:14:32 pm
Thanks, Scotty!

Oddly enough, 3/4 of the way towards having my new tail section mounted, I'm back to considering a different ass-end.

(https://lh3.googleusercontent.com/-cpwWHyj2xoM/TYPiVHrztOI/AAAAAAAABV4/i4bMe6T1aSA/s1600/le-69-t120-3.jpg)

This style would be pretty cool, although I'm 1) not sure how comfy a Bates style solo seat would be with rearsets and 2) I'd need a new place to stash the electrics; probably in the toolboxes.

Or behind side covers I put in place of the toolboxes.


God, I'm a mess.  (edit:  especially because I also find the bike below to be inspirational...metal rear section and all.)

(http://www.bikeexif.com/wp-content/uploads/2012/10/norton-commando-1.jpg)

(http://www.bikeexif.com/wp-content/uploads/2012/10/norton-commando.jpg)
Title: Re: My New Plan
Post by: ace.cafe on June 09, 2013, 03:38:08 am
I think that the Bullet frame presents a more difficult challenge because the frame lacks the straight line from the tank back to the shock posts, and instead drops low, more like a hardtail. This creates a special visual issue that most of the bikes like Triumph and Norton and Rickman didn't have to deal with. It has that triangle area under the seat that makes it harder to get a smooth line there.
Title: Re: My New Plan
Post by: AgentX on June 09, 2013, 03:57:32 am
I think that the Bullet frame presents a more difficult challenge because the frame lacks the straight line from the tank back to the shock posts, and instead drops low, more like a hardtail. This creates a special visual issue that most of the bikes like Triumph and Norton and Rickman didn't have to deal with. It has that triangle area under the seat that makes it harder to get a smooth line there.

Absolutely.  There's a need to fabricate a sub-frame for most alternate seat options.  A solo fits in nicely if you're using springs, but as I think a sprung seat on a swingarm bike looks odd, I'd be looking at a big gap under a rigid-mounted solo, too.  (unless you buy the Indian rigid-mount couch that covers the gap...no thanks...)  Or unless you get the seat really cocked-back, which would be cool for a slightly exaggerated cruiser-ish stance when used with a really dished seat pan.

But then again, that gap could be perfect for reg/rect, ignition box, and maybe coil...
Title: Re: My New Plan
Post by: GSS on June 09, 2013, 04:28:30 pm
The sub-frame for the C5 OEM pillion seat provides a very nice platform for seat and cafe modifications.  Maybe you could consider fabricating something similar for your Bullet.
Title: Re: My New Plan
Post by: AgentX on June 09, 2013, 05:55:57 pm
The sub-frame for the C5 OEM pillion seat provides a very nice platform for seat and cafe modifications.  Maybe you could consider fabricating something similar for your Bullet.

That's the plan.
Title: Re: My New Plan
Post by: AgentX on June 23, 2013, 04:22:05 pm
Will get a look at the seat subframe tomorrow--having it welded in the late hours before I split the country.  New gauge cluster should be done this week, too.  Hopefully it all comes out well...if not, it was a cheap experiment.

Chumma was recently through India and was kind enough to drop by my place.  Gave me a lot of stuff to think about. 

Here's what I'm shooting for after the rebuild:

Engine/drivetrain:
-Fireball package on a 2002 engine with the coated chamber and piston, barrel cryo'd.  Magnum cams/TM32 carb per spec.
-Newby belt primary
-5spd right-shift transmission
-Spin-on oil filter, oil plumbing either Chumma's standard copper tubing, or possibly with braided stainless hose.  (flexible, which I equate to durable in this application.)
-Stock header chopped to 32" with the cheap Emgo megaphone on it.  Dreamed of stainless custom, but this'll do for now and still look awesome.  Plus I can glass-pack the crap out of it to try and keep it from deafening me.

Suspension:
-Fork cartridge emulators from YSS
-Rear Hagons with adjustable damping (310mm)

Electrics:
-Upgraded alternator
-Boyer micro-digital ignition and powerbox R/R
-Home-built wiring harness
-Halogen lamp (ditching the current cheap Chinese HID experiment), probably a 5 3/4 Bates-style bottom-mount bucket supported by a bracket on the lower crown
-Dual LED rear tail lights and LED gauge lamps

Chassis:
-Frame sent for alignment
-Seat/tail:  alloy unit I had custom-made, mounted to sub-frame with electrics and storage tray underneath.  Seat removable via quarter-turn dzus fastener to access tray. 
-Rear-set pegs moved forward an inch and a half or so, with clean mounts to replace the bodged-up mess on there now.
-Excel alloy rims (probably valenced, but the jury's still out; maybe just the dimpled standard rim) WM2 front, WM3 rear  with stainless swaged spokes.  K70 tires.
-Front disc
-Possibly:  disc brake tab welded to swingarm, derived from the Indian disc brake rear kit, with bosses for the slave and master cylinder.  (Both to make my rear brake more usable with my rearsets and to make user-level maintenance easier...I can rebuild a caliper, but not cut a drum or arc pads.)
-Also possible:  tapered head bearings in custom-machined cups

Controls:
-"Thunderbird" triple trees (as I have now, eliminating casquette)
-Dirt-trackish bars, probably Emgo "Magna Wide" in chrome (http://www.motorcycle-superstore.com/14/71/982/36824/ITEM/Emgo-Wide-Magna-Handlebars.aspx)
-Motion pro "turbo" throttle (http://www.motionpro.com/motorcycle/partno/01-0057/).
-Low-profile bar switches from Highwaydirtbikes (http://www.highwaydirtbikes.com/HDB_Shop/index.php?app=ccp0&ns=prodshow&ref=BrakePerSw_2) for hi-lo, kill, and horn.
-Main light on/off via toggle switch in gauge cluster.
Title: Re: My New Plan
Post by: AgentX on October 18, 2013, 03:17:21 pm
Got the seat/tail mounted in the 8th hour before leaving for the States.  I like the tank and carb in proximity to the torch--note I zoomed in from across the street for the photo.  :)

(http://i6.photobucket.com/albums/y218/MikesBikes/IMG-20130706-00085_zpsecdb75dd.jpg)

Now in the US with work underway by a very talented fabricator in Providence, RI, Tom McVay.  Top end work is done at Ace, and Chumma will be working on a bottom end over the next few months.

First order of business locally: locating the footpegs in a true mid-set position.  Clearance of the primary and transmission cases is an issue.  Tom's also going to fabricate a wraparound style kicker that goes under the pegs back to the toolboxes; by eliminating the bulky hinged arrangement on the standard 5spd lever, we can tuck the control lever in tighter.

After that, he's going to fab up a wraparound kickstart lever to sit behind the pegs, with the peg tucked up under the toolbox.  This will also allow the pegs to tuck in tighter to the frame, by eliminating the bulky folding component of the stock kicker.


(http://i6.photobucket.com/albums/y218/MikesBikes/IMG_20131016_162135_zps53348dc7.jpg)

(http://i6.photobucket.com/albums/y218/MikesBikes/IMG_20131016_162147_zpsb8a75008.jpg)


Tom will also do:

-Rear disc brake mount (floating)
-Alloy seat subframe, to replace heavy steel one
-New clean mount on the downtube for my spin on oil filter
-Stainless exhaust (after bike's complete)

Once the fab work's done, going to get the frame aligned.  Have to work out getting transmission, hubs, and a bunch of other stuff to Chumma.  Paint/powder/any finishing is a chafe because of the bike and the engine being in different places.  Logistics suck!
Title: Re: My New Plan
Post by: ace.cafe on October 18, 2013, 07:32:18 pm
Looking good!
Love the alloy tail section!
 8)
Title: Re: My New Plan
Post by: 1 Thump on October 18, 2013, 08:08:13 pm
This is my absolute favorite RE cafe. I like the way the subframe was used for the cafe seat.
Title: Re: My New Plan
Post by: AgentX on October 19, 2013, 12:56:26 am
This is my fave.  The seat is ostensibly Hitchcock's, but I believe it's a rebranded "Glass from the Past" seat model made specifically for the Enfield.  Talked to GFTP last year about it; they said supports need to be fabbed but they can provide the plans.


(http://www.hitchcocksmotorcycles.com/news/30542//pictures/content267/gpad3.jpg)
Title: Re: My New Plan
Post by: AgentX on October 19, 2013, 01:00:19 am
Looking good!
Love the alloy tail section!
 8)

Thanks Tom!  It's sort of out of place with the rest of the bike in olive drab, but the alloy rims will help offset it.  Originally the new engine cases were going to be raw alloy, too, so I thought there'd be a lot of bright alloy, but now Chumma's got an 06 US military bottom end he wants to use.  Which is yet another shade of OD.

It's a mongrel so I'm not too worried about it any way it shakes out.  The idea of a silver or nickeled frame is becoming more appealing, though...hmmmmmmmm.

Edit:  By the way, the seat was made by a talented guy named Ken Hosford.  He does seats in mild/stainless/alloy for between $100-200 depending on design and material.  Full custom.  Also does fenders and the like.  Great dude.  If anyone wants his contact info, let me know and I'll put you in touch with him.
Title: Re: My New Plan
Post by: D the D on October 19, 2013, 03:14:03 am
Looks good the way it is too!  Kind of old and '40s/'50s -ish.  Somehow I don't envision you ever being done = you're going to keep having ideas.... ;)
Title: Re: My New Plan
Post by: AgentX on October 20, 2013, 08:51:51 pm
Opinions wanted:  would a contrasting silver or nickel finish frame against the OD green tank/cases/toolboxes/fork lowers look good?

Was looking at nickeled Rickman and other classic frames at Barber and they were amazing.  Just not sure if I can carry the look on this one.
Title: Re: My New Plan
Post by: AgentX on October 28, 2013, 11:46:49 pm
(http://i6.photobucket.com/albums/y218/MikesBikes/20131024_190711jpeg_thumb_zpsad08a19d.png)

My fabricator kicks ass.  Peg mounts shaping up. He's going to add another support running vertically to each side.

If you're in Rhode Island and need some custom work done, go see Tom.

Title: Re: My New Plan
Post by: AgentX on December 24, 2013, 04:48:21 pm
I am now the proud owner of a basket case.

Ratchet strap to pull off the head; needed some gentle tapping with a mallet around the edge combined with the force from the strap.  Very tricky to get purchase from the hook in the exhaust outlet.

(http://img.tapatalk.com/d/13/12/19/gapanysy.jpg)

Somehow I got the feeling the bike was resisting disassembly. 

(http://img.tapatalk.com/d/13/12/19/u3yzy5e8.jpg)

But eventually it came out.

(http://img.tapatalk.com/d/13/12/20/ezateqa9.jpg)

Trying to find a pic of the wheel/fork-less chassis resting on the centerstand with a photo tripod propping up the front but no luck.


Got major parts at paint; waiting for them to get done so I can get cases, primary, and transmission to Chumma soon.  Unfortunately I'll be (finally) deploying before that's finished...maybe I can work things via remote control through wife and family back home, or will just take care of it in a few months.
Title: Re: My New Plan
Post by: AgentX on December 24, 2013, 04:59:32 pm
Oh, don't think I ever showed the mount for the spin-on filter either.  In a safer place than it was before, which was down low behind the front wheel.  Horn's now tucked up nice under the tank, too. 

(http://www.dotheton.com/forum/index.php?action=dlattach;topic=54115.0;attach=102906;image)

(http://www.dotheton.com/forum/index.php?action=dlattach;topic=54115.0;attach=101849;image)
(Added a bit to the engine plate to mount the filter)

Don't mind all the dirt and crud.  Everything's getting stripped and cleaned, much of it being re-painted.
Title: Re: My New Plan
Post by: AgentX on March 15, 2014, 01:20:40 pm
I am sitting on an Amtrack with the majority of an engine in a backpack.  Heading through NJ on my way out to central Africa next week--will be dropping painted cases, primary, transmission, and other bits with Chumma to get built up.  Head and barrel are done already.  Hubs to be sent to Buchanan shortly.

Frame's been further modded for a disc brake and alignment checked. Seat is in for upholstery by a certified mad scientist of leather and foam. Gonna look slick.

Once done, this will all get back to my home somehow in my absence, so it can be packed up with the rest of my stuff and delivered sometime late summer in Africa, where I'll finish building it back up.

Unfortunately, was unable to get the stainless header made in the US, nor the kickstarter modification I will likely need to clear the footpegs.  (Or at least wanted, to look slick...making it a wrap-behind design, like this 80-gbp Hitchcock piece...)

http://www.hitchcocksmotorcycles.com/http://www.hitchcocksmotorcycles.com/pictures/category5545/large/KICKSTART.jpg (http://www.hitchcocksmotorcycles.com/http://www.hitchcocksmotorcycles.com/pictures/category5545/large/KICKSTART.jpg)

I really, really cannot wait to have a running bike again.  But it's a long road.  Still, even if it was running, I wouldn't have had the chance to really ride it since last July, so it's good I can get the work done now.

I've drawn and re-drawn the wiring diagram for this thing a million times.  Think I'm settled on the nearly-simplest-possible variant.
Title: Re: My New Plan
Post by: barenekd on March 15, 2014, 07:23:26 pm
Where are you now? No still in Germany?
Bare
Title: Re: My New Plan
Post by: AgentX on March 15, 2014, 11:31:59 pm
Where are you now? No still in Germany?
Bare

Germany?!   Way too nice for them to ever send me there...hell, I rarely even get to lay over there long enough for a wurst and a beer near the departure gate.

I was in India till last July; was supposed to go to parts nasty and explosive in the fall, but didn't get the required visas, so took a temp job in Chad for a bit.  Now heading out to Mali for a few years.

Oh, and saw Chumma this afternoon.  So psyched to have the parts in his hands!!!
Title: Re: My New Plan
Post by: AgentX on July 07, 2014, 08:24:27 am
Well, things never go as planned...was hoping to have the engine in chassis during a short stint back in the States, but that didn't work out timing-wise.

Chumma did some awesome stuff with my engine, though...sneak preview of a few things.  Drilled primary to vent the Newby clutch, did some welding and refinishing to deal with the mangled breather elbow from a previous owner of this engine case, crank...etc. etc.


(http://www.dotheton.com/forum/index.php?action=dlattach;topic=54115.0;attach=122212;image)

(http://www.dotheton.com/forum/index.php?action=dlattach;topic=54115.0;attach=122474;image)

(http://www.dotheton.com/forum/index.php?action=dlattach;topic=54115.0;attach=122476;image)

(http://www.dotheton.com/forum/index.php?action=dlattach;topic=54115.0;attach=122477)

(http://www.dotheton.com/forum/index.php?action=dlattach;topic=54115.0;attach=122479)

(http://www.dotheton.com/forum/index.php?action=dlattach;topic=54115.0;attach=122481)



But, today's the day...Chumma is bringing the finished engine up to Rhode Island to put into the frame for packing to Africa tomorrow!  He will get an assist on labor from a friendly rider I met over the summer.  Ultimate goal is a rolling frame on the new Excel wheels.

Hope to have some pics soon.  But mostly I hope everything goes smoothly.  Super-bummed to not be there to make it happen.
Title: Re: My New Plan
Post by: AgentX on July 07, 2014, 08:30:38 am
(http://www.dotheton.com/forum/index.php?action=dlattach;topic=54115.0;attach=120430;image)

Seat's upholstered, too.  Kind of a debacle and not what we'd planned but looks pretty slick.

Finish work has been a huge problem; bike is half in powder half in paint and neither is the exact shade I wanted, nor do they match.  But I'm just happy it'll be weather-protected, durable, and running at this point.  I'll just rip though the African dust and sand and mud and dirt till everything's nice and covered/faded/worn/beaten until that sort of thing doesn't matter anymore.
Title: Re: My New Plan
Post by: High On Octane on July 07, 2014, 01:48:03 pm
It's been so long I forgot you even had another project.    ::)  Glad you are making progress tho.  Sorry to hear that your paint doesn't match, that's a bummer.  Hopefully it's minor enough that only the owner and a trained eye will see it.    ;)    I kind of envy you guys that get to travel all over the world for work.  I get to drive down the exact same crowded-ass-over-packed freeway everyday.  The drive gets old.     :-\

Scottie J
Title: Re: My New Plan
Post by: AgentX on July 07, 2014, 04:22:15 pm
It's been so long I forgot you even had another project.    ::)  Glad you are making progress tho.  Sorry to hear that your paint doesn't match, that's a bummer.  Hopefully it's minor enough that only the owner and a trained eye will see it.    ;)    I kind of envy you guys that get to travel all over the world for work.  I get to drive down the exact same crowded-ass-over-packed freeway everyday.  The drive gets old.     :-\

Scottie J

Hah, I don't have *another* project...just the same old drawn out angonizing one I've been boring people with for like 2 years now.

As far as the paint goes, it'll be so mismatched it might actually look intentional.  Chumma had to apply a patch of paint over the case where the breather repair was done, even.  It'll just be a patchwork, which in some ways might look authentically military, lol.

I'm over wringing my hands about it.  If I was in the States, I'd buy some RAL-standard-color automotive spray paint and repaint it all myself over the existing good-quality paint and powder already on there.  But I'm not, so screw it.  Can't order spray paint through the mail here and not gonna waste any more time/money/effort on it.

Next time the engine's out of the frame I'll consider giving it a thorough cleaning and prep for an even coat of paint...or I'll just be enjoying its mongrel-dom too much to care.  :)

Here's hoping Chumma's got things well in hand so far today.
Title: Re: My New Plan
Post by: ace.cafe on July 07, 2014, 04:55:27 pm
He just called me.
He is on the way to the delivery point.
He left several hours ago, so he should be nearly there.
Title: Re: My New Plan
Post by: AgentX on July 07, 2014, 05:50:04 pm
Arrived a short while ago.  :)
Title: Re: My New Plan
Post by: AgentX on July 07, 2014, 11:09:22 pm
(http://img.tapatalk.com/d/14/07/08/ytugabe5.jpg)

(http://img.tapatalk.com/d/14/07/08/du8yzuha.jpg)

Oh

My.
Title: Re: My New Plan
Post by: ace.cafe on July 07, 2014, 11:21:58 pm
Chumma does very nice work!
 8)
Title: Re: My New Plan
Post by: AgentX on July 08, 2014, 12:55:35 am
(http://www.dotheton.com/forum/index.php?action=dlattach;topic=54115.0;attach=122665)

(http://www.dotheton.com/forum/index.php?action=dlattach;topic=54115.0;attach=122664;image)

Ho-leee-eee crap.
Title: Re: My New Plan
Post by: High On Octane on July 08, 2014, 01:44:03 am
Sweeeeet!!!!!    :D
Title: Re: My New Plan
Post by: AgentX on July 08, 2014, 02:02:10 am
Chumma was aided by another friend, a rider I met briefly at a local dive where I had taken my four year old for dinner.

Scoped the Honda cafe racers outside and realized the riders were members of another website I participate in, dotheton.com.  Got this guy in touch with my fabricator and in exchange, he agreed to help me with this project.  Called in the favor and he was Johnny on the Spot to help out Chumma.  Truly a generous act.

Cheers and beers to these two superheroes!

(http://www.dotheton.com/forum/index.php?action=dlattach;topic=54115.0;attach=122667)
Title: Re: My New Plan
Post by: Chuck D on July 08, 2014, 01:27:33 pm
Chumma does very nice work!
 8)
Was gonna give him a ring but I think I'll let him sleep.
Title: Re: My New Plan
Post by: Chuck D on July 08, 2014, 01:29:18 pm
AgentX... your bike is going to be killer! Enjoy!

Chuck.
Title: Re: My New Plan
Post by: AgentX on July 08, 2014, 02:44:09 pm
Thanks, Chuck.

But mostly thanks to Tom and Chumma...  having the engine hand-delivered and installed in the frame was critical for me.  A real above and beyond.

Wish we could have sync'd it up so I was there to assist, but mostly I'm just psyched it'll be packed and on its way soon!
Title: Re: My New Plan
Post by: AgentX on October 03, 2014, 04:17:57 pm
It has arrived...!  Laid the seat and tank into place before getting on with the unpacking of the house...bars are still upside down from shipping.

Now I have more work ahead of me than I had really anticipated.  There is a LOT of stuff to do.
Title: Re: My New Plan
Post by: High On Octane on October 03, 2014, 05:20:22 pm
Cool!  I like that new seat/tail  section.   :)
Title: Re: My New Plan
Post by: ERC on October 03, 2014, 10:47:38 pm
There's way to much stuff hanging from your walls. Like the bike though.  ;D  ERC
Title: Re: My New Plan
Post by: boggy on October 04, 2014, 12:24:27 am
So it looks like you have a brace going from the inside of the shock's mount up to the seat, is that right?  Pretty cool idea.  Been trying to think of way to get a flat seat on the frame.

Really dig the Thunderbird fork setup.
Title: Re: My New Plan
Post by: AgentX on October 04, 2014, 07:24:27 am
So it looks like you have a brace going from the inside of the shock's mount up to the seat, is that right?  Pretty cool idea.  Been trying to think of way to get a flat seat on the frame.

Really dig the Thunderbird fork setup.

There's a nub welded onto the top of each shock mount, and the aluminum seat tray has legs which fit over the nubs.  The nub is drilled and tapped for a small machine screw and there's a corresponding hole in the seat tray leg.

In front, the flat aluminum pan is bolted through to a small threaded boss on either side of the main tube.


If you used a clevis-type end on the seat tray leg, to fit on either side of the shock mount with the mounting bolt going through, it might be a simpler way to mount it up on the rear.  I left my fabricator alone with the frame for a few days and he did this arrangement for me... 

I like the Thunderbird forks too, but a set of custom or Hitchcock crowns may be in the works for someday.  It's kind of heavy and ungainly.  Would be nice to go to a standard dual triple-clamp arrangement instead of the bolt-through-the-top setup.

I do have these head bearing cups on the way, too:

(http://www.enfieldmotorcycles.com/forum/index.php?action=dlattach;topic=20216.0;attach=24871;image)
Title: Re: My New Plan
Post by: mattsz on October 04, 2014, 11:14:25 am
(http://www.enfieldmotorcycles.com/forum/index.php?action=dlattach;topic=12334.0;attach=25237;image)

;D

Hurry up and get my new bike off that truck - I wanna ride it!!!
Title: Re: My New Plan
Post by: AgentX on October 04, 2014, 01:23:59 pm
Cool!  I like that new seat/tail  section.   :)

Thanks...like the rest of the bike it's a bit rough and ready but it suits.  Equipped with three captive Dzus fasteners to take it off/on and access the under-tray for the electrics etc.  Got twin tail lights and a license bracket (conveniently acting as a mudcatcher) built in, too.

It came to me raw aluminum...I had it polished in India since that's super-cheap there, but then its handling by the guys who fabbed the first seat mount brought it back to quite beaten and scratched up. 

Debating the final iteration; might even paint it to (mis-)match the rest of the bike, which is at least 5 different shades of olive drab now.  Even the case halves are mismatched to one another and the transmission (which itself is mismatched between case and cover).  But the metal also catches some of the new shinier bits like the alloy rims etc.  For now, it's just someplace to hopefully put my ass eventually when it moves.  I'll worry about the finish later.  The upholstery might be the first issue to tackle.  The guy who I used charged a ton and made a gorgeous seatcover, but the underlying padding is half taken up with a piece of skillfully bent wood as a seat pan.  Might be a little to firm even for my bicyclist's derriere.

I was pretty miffed, seeing as I'd paid him to do a snap-on cover with an inch and a half of foam underneath.  It was a big mix-up as to how I ended up using him...he shares his shop with a different guy who does cafe seats regularly.
Title: Re: My New Plan
Post by: High On Octane on October 04, 2014, 01:37:44 pm
I just had a thought X.  I remember you mentioning before that the all the OD Green is mismatched, but I have an idea for getting it all to blend and not notice and still be within your theme.  What if you painted your bike with a ODG digital camo theme?  ???

(http://i6.photobucket.com/albums/y217/lethalinj/DigiCamo_zps7404bc1e.jpg) (http://s6.photobucket.com/user/lethalinj/media/DigiCamo_zps7404bc1e.jpg.html)
Title: Re: My New Plan
Post by: AgentX on October 04, 2014, 01:42:03 pm
I just had a thought X.  I remember you mentioning before that the all the OD Green is mismatched, but I have an idea for getting it all to blend and not notice and still be within your theme.  What if you painted your bike with a ODG digital camo theme?  ???

(http://i6.photobucket.com/albums/y217/lethalinj/DigiCamo_zps7404bc1e.jpg) (http://s6.photobucket.com/user/lethalinj/media/DigiCamo_zps7404bc1e.jpg.html)

Not really my cup of tea...would be a good way to get it all to blend, but that's work/time/money/effort I don't have anyhow.  It's f'n ugly. (ed:  the bike as it stands, that is...) I don't mind.  I once deliberately keyed my own tank to prove a point to an aghast Indian painter who was desperate to give me a "cool" paint scheme.
Title: Re: My New Plan
Post by: High On Octane on October 04, 2014, 02:07:25 pm
Not really my cup of tea...would be a good way to get it all to blend, but that's work/time/money/effort I don't have anyhow.  It's f'n ugly.  I don't mind.  I once deliberately keyed my own tank to prove a point to an aghast Indian painter who was desperate to give me a "cool" paint scheme.

I understand, not really my thing either.  Like I said, just a thought.  But that is awesome about keying your own tank.  Honestly, I'm still riding around with a Super Meteor sized crater in my Super Meteor (Trailblazer) gas tank.   ;D  It has since lost a chunk of body filler and paint since I took this pic.  I'll fix it one of these days.  ;)

(http://i6.photobucket.com/albums/y217/lethalinj/Carnage1_zpse760177e.jpg) (http://s6.photobucket.com/user/lethalinj/media/Carnage1_zpse760177e.jpg.html)

Title: Re: My New Plan
Post by: AgentX on October 05, 2014, 11:15:49 pm
Hardly a monumental day.  Got the tank stud buffer into the frame.   ::)  Mocked up the kicker and it clears the new footpegs when folded, so whoopee for that; shifter linkage rod will work, too.  Filed out the mounting tabs on the tank so that the rear tank stud would actually pass through them.

And got stuck trying to replace the footrest support hex rod with a shorter one.  (With the new peg position, it serves no purpose, so I just want to clean up the look instead of a long goofy bar with spacers sticking out into nowhere...)

I tried to drift the old one out using the new one to avoid any shifting of the engine mount plates, but that didn't work, and now I can't get the new rod through.  Tomorrow I'm going to put both sides of the frame up on jacks, supporting the empty footpeg mount bosses, and hope that supporting the frame from there lets me get the rod through by flexing the 1mm or so I need to line things up.

Other than that, I mocked up the under-seat electrics tray and took a photo and labeled it so I don't forget!  (attached)
Title: Re: My New Plan
Post by: AgentX on October 05, 2014, 11:24:50 pm
I'll fix it one of these days.  ;)

See?  Such a heavy obligation having a nice-looking bike!! 

Edit:  finally got the footrest bar in...supported frame on both sides at the footrest bar bosses with a friend helping steady the bike, and with a little downward pressure on the frame, it slipped in.  Fumbled with spacers for a bit and got it completely through.  Little nub left over needed about an inch of spacer so I could snug it down tight.

It's these little things that make this job hard!
Title: Re: My New Plan
Post by: AgentX on October 13, 2014, 11:07:13 pm
(http://tapatalk.imageshack.com/v2/14/10/13/0e9c5e6f49e678942dda2589a12b61fb.jpg)

(http://tapatalk.imageshack.com/v2/14/10/13/bdfdb998ec8badf4264924c44c59ac3c.jpg)

Got the shift linkage and kicker set.  (Nevermind the direction of the folded peg--just worked out that way for this mockup.)

More interestingly, I had the African Machine Shop adventure this morning, getting the stem prepped to take the taper roller bearing for the new headset setup.

Big on color, awesome old lathes, and the most voluminous collection of blocks and cranks on earth.  Not big on safety gear.  But they did like surgical masks if not shoes, eye pro, or gloves.

(http://tapatalk.imageshack.com/v2/14/10/13/3aa5694948f1ca74c4345e7ed592b819.jpg)

(http://tapatalk.imageshack.com/v2/14/10/13/f3ed727d50517d25070b50fe2ab8d598.jpg)

(http://tapatalk.imageshack.com/v2/14/10/13/65cfcab0abf02bdc80ac879196cd84cf.jpg)

(http://tapatalk.imageshack.com/v2/14/10/13/d5b9d4d21ca34eae4339a9aa32581375.jpg)

(http://tapatalk.imageshack.com/v2/14/10/13/9003998c8e9952f90e7ac754dc5f0ca9.jpg)

(http://tapatalk.imageshack.com/v2/14/10/13/6c0be4e7fc3db80c5a2ac63d394c24fc.jpg)
Title: Re: My New Plan
Post by: AgentX on October 26, 2014, 06:51:30 am
Carb and airbox mounting.  Have some interference with tank mount tabs so I will have to get some grinding going to make it fit together.

(http://tapatalk.imageshack.com/v2/14/10/25/e3969dd5f76d3b12d6092282e079bdc0.jpg)

Getting started with the oil hosing.  From cases to external filter, up to forward head oil input, and across to the rear.

(http://www.dotheton.com/forum/index.php?action=dlattach;topic=54115.0;attach=130252;image)

(http://www.dotheton.com/forum/index.php?action=dlattach;topic=54115.0;attach=130250;image)
Title: Re: My New Plan
Post by: AgentX on October 26, 2014, 09:49:30 am
The ritual autumn "making o' the hoses."


(http://tapatalk.imageshack.com/v2/14/10/26/d6dfd380a1797e3f52a28282b64be86b.jpg)

Earl's Speed-Seal hosing hates dremel cutting wheels, or vice-versa...went through wheels crazy-fast, but cutting and assembly were pretty damned easy.

(http://tapatalk.imageshack.com/v2/14/10/26/5396c5e3f42776a15a49e639b3cdf6ed.jpg)

(http://tapatalk.imageshack.com/v2/14/10/26/f493989e2aa724b032a6a548602a3da8.jpg)

Lessons in braided lines:  There's a natural curve to the line, so make sure you design that in, and torque your hose-ends to be in a good position when the line sits naturally when using a banjo end.  You have a little bit of wiggle room in how much you tighten, so you can alter the position of the banjo just a tad.  Helps if you're not fighting against a twist it as you try and thread the banjo and two compression washers into the aluminum haed.


(http://tapatalk.imageshack.com/v2/14/10/26/ab0bfbd218004037f842231c32bfd472.jpg)
Title: Re: My New Plan
Post by: High On Octane on October 26, 2014, 04:22:47 pm
I love the stainless oil lines!  Where did you source those?  I think I'm going to have to do that to the Blackhawk.  Looking good!  :D
Title: Re: My New Plan
Post by: AgentX on October 26, 2014, 05:33:42 pm
I love the stainless oil lines!  Where did you source those?  I think I'm going to have to do that to the Blackhawk.  Looking good!  :D

Thanks!

NPT adapters in filter, cases, and head needed to be drilled and tapped for m10x1.25 banjo bolts. 

Lots of brands of hose and hose ends, but I chose Earl's performance speed-seal in zinc finish because they had the only m10 banjo to an3 hose fitting I could find.  JEGS is a great source for this kind of stuff because of free shipping.  I got my setup from an plumbing.com.  Summit is another good choice.

FYI I have the Ace hi-flow oil system and Chumma and I decided on an4 hose up to the double banjo head feed, with an3 feeding off of there to the second head input.
Title: Re: My New Plan
Post by: Blltrdr on October 26, 2014, 06:32:37 pm
Do you get equal or sufficient oiling to your intake side with this hose arrangement?
Title: Re: My New Plan
Post by: AgentX on October 26, 2014, 06:48:42 pm
Do you get equal or sufficient oiling to your intake side with this hose arrangement?

Can't start the engine yet to say for certain, but obviously that is the anticipation.

My original plan was a tee fitting to both intakes, but Chumma felt this was a simpler way to accomplish the same thing.  The RE factory accessory(to best of my knowledge) oil cooler fitted to the Fury routed this way, too.

With the hopped up hi-flow oil system, I sincerely doubt we will see a lack of oil at the intake rocker, but it will be the first place I check on startup.

Edit:  here is the Fury

(http://3.bp.blogspot.com/-ri4kCSQjpsc/UuQeLCElIoI/AAAAAAAAeWQ/S8_EMH60ouM/s280/1960_Royal_Enfield_Fury2.jpg)
Title: Re: My New Plan
Post by: Blltrdr on October 26, 2014, 06:51:18 pm
Can't start the engine yet to say for certain, but obviously that is the anticipation.

My original plan was a tee fitting to both intakes, but Chumma felt this was a simpler way to accomplish the same thing.  The RE factory (to best of my knowledge) oil cooler fitted to the Fury routed this way, too.

With the hopped up hi-flow oil system, I sincerely doubt we will see a lack of oil at the intake rocker, but it will be the first place I check on startup.

Well everything you have done so far looks well thought out. Good job.
Title: Re: My New Plan
Post by: AgentX on November 16, 2014, 02:20:12 pm
OK, I think my tacho is happy up front in the cut-down pod.  Any votes for where to tuck in the speedo?  (Snigger) sorry for crap pic quality in this thread.

(http://tapatalk.imageshack.com/v2/14/11/16/5eca639f2ec9c9a39ef5fcf358d39b8e.jpg)

(http://tapatalk.imageshack.com/v2/14/11/16/d21ecc74cadd227e03a44fc3f99d8bdc.jpg)

(http://tapatalk.imageshack.com/v2/14/11/16/e8d8ad6bc05370a90e92334eaedc1bdf.jpg)



I think alongside the tach but vertical gets my vote.  Second to alongside the fork leg.

(http://tapatalk.imageshack.com/v2/14/11/16/f571b97f8ba843d90a147339589542d0.jpg)

(http://tapatalk.imageshack.com/v2/14/11/16/ab04adfae2c4edb3231212610385cc1b.jpg)

(http://tapatalk.imageshack.com/v2/14/11/16/70dfbb3bc3f20ff398ed0fa3d2607682.jpg)

Made the throttle cable, too.  $20 Chinese electric solder pot makes it super simple to put on cable ends...guess it is more expensive than a $2 pipe end fitting, but I don't have a torch to melt the solder.  Either way, totally worth it over using the electric soldering iron.  60/40 solder and red liquid flux.  Dip.  Boom.  Done.  Solder exactly where I need it, in appropriate amounts, without overheating the wire or stiffening it with excess solder wicking.
Title: Re: My New Plan
Post by: High On Octane on November 16, 2014, 02:30:12 pm
Do you legally need the speedo?  I personally love the look of a big ol' tach (and maybe a couple of engine gauges) without the speedo.  But maybe that just stems from my '75 Formula 350 Firebird snapping the speedo cable twice wrapping the needle past 100mph and back around to about 30mph mark.  ;D  But if you need/want the speedo on there, I'd go with the 1st position.
Title: Re: My New Plan
Post by: AgentX on November 16, 2014, 05:10:38 pm
Need an odometer is the issue.
Title: Re: My New Plan
Post by: High On Octane on November 16, 2014, 06:13:58 pm
Need an odometer is the issue.
For fuel/mileage purposes?  How about a sleek hour meter instead?    ???  Either way, your bike is going to look sick when your done.  :D
Title: Re: My New Plan
Post by: AgentX on November 16, 2014, 08:36:44 pm
I think I can get a fork leg bracket knocked out by the machinist who has been helping me out.  Just two round clamps in a figure 8.
Title: Re: My New Plan
Post by: mattsz on November 16, 2014, 09:11:18 pm
will it be "right-side-up"?   ;)
Title: Re: My New Plan
Post by: AgentX on November 16, 2014, 10:04:48 pm
will it be "right-side-up"?   ;)

I like the option to go inverted, just in case there's a MiG around.

(http://genuineindividual.com/wp-content/uploads/2012/11/Maverick-And-Goose-Tom-Cruise-Top-Gun-Inverted-With-Mig-1280-Wallpaper-2.jpg)
Title: Re: My New Plan
Post by: ace.cafe on November 16, 2014, 11:13:09 pm
I like it alongside the tach.
Title: Re: My New Plan
Post by: AgentX on November 20, 2014, 07:10:18 am
I am asking my machinist to knock together a simple clamp to mount it to the fork leg, and probably tuck it up high next to the tach.
Title: Re: My New Plan
Post by: barenekd on November 21, 2014, 09:31:01 pm
I always wondered how those two planes didn't remove some rudders in that maneuver! Dumb s%*t movies.
Bare
Title: Re: My New Plan
Post by: AgentX on November 22, 2014, 05:24:46 pm
I always wondered how those two planes didn't remove some rudders in that maneuver! Dumb s%*t movies.
Bare

(http://flyingwairport.com/wp-content/uploads/2014/07/top-gun-volleyball-embrace.jpg)
Title: Re: My New Plan
Post by: AgentX on November 22, 2014, 05:43:44 pm
In other news, progress-wise:

Headlamp mounted, and I wired a toggle in for the main power relay, and put a daylight-visible LED behind the little blue indicator light (originally planned to be exterior, but it was just too bright and would be way too bright for night use); the light will illuminate when main power is on.  Anti-theft will be taken care of via a switch arrangement elsewhere.  No key.  Electrical work is much more fun now that I have lots of spare crimp connectors, proper tools, and good adhesive heat shrink.

Header pipe is being problematic.  It would only pound in partway, building a ridge of aluminum from the head as it went in at two tight spots, yet was really loose except the those two tight spots. Thought the pipe was football shaped but it actually seems to be the head opening.  I have an expander and am gradually trying to bring the port and the pipe to the same size and shape using wet-dry paper and some dead reckoning.  The front bracket also seems too short, so I will probably cut off the front mounting hole tab, pop-rivet a longer piece of aluminum alongside the remains of the metal bracket, and bend/drill the aluminum to fit.  Then mounting the muffler tucked behind the rearsets becomes the next challenge.

Speedo will likely go in a bracket that mounts to the fork stanchion, placed next to the tach, but with the top bezel even-ish with the fork crown.

Got some aluminum stock to start making brackets and such, and some more basic supplies.

Think I have to re-make the throttle cable, as this one's got zero slack even with the adjusters totally backed out.
Title: Re: My New Plan
Post by: AgentX on November 24, 2014, 07:15:08 am
Electrics tray shaping up

(http://tapatalk.imageshack.com/v2/14/11/23/4056b5278ca01b5fe0ea230112ae1aba.jpg)

From the tray, there will be a wire run on the left for bar switch and gauges, and oneon the right for ki, front brake, and headlamp power.  Everything else except the rear brake switch is inside the tray.
Title: Re: My New Plan
Post by: High On Octane on November 24, 2014, 10:07:57 pm
I like the electric tray.  I might have to steal that idea from you.
Title: Re: My New Plan
Post by: AgentX on November 24, 2014, 10:14:48 pm
I like the electric tray.  I might have to steal that idea from you.

Only one detail is top secret.  :D
Title: Re: My New Plan
Post by: AgentX on November 29, 2014, 07:13:24 pm
(http://tapatalk.imageshack.com/v2/14/11/29/6e67bdeb5dcd5a0ad0a5d583a88e09eb.jpg)

(http://tapatalk.imageshack.com/v2/14/11/29/f01761f7754a61287006c0a8ce1f25f4.jpg)

(http://tapatalk.imageshack.com/v2/14/11/29/b6ea9ae6b6f3a353f364092e65554625.jpg)

Tach after all!  "Crude but effective" is an understatement in both aspects.  Just two strips of 6061 stuck to one another and the tach pod mount with ginormous pop rivets.  Threaded holes in the front end of the crown let it mount up easily.

The header pipe, on the other hand, is driving me f'n nuts.  Grrrrr.  I hate hate hate hate the friction fit design, especially when coupled with Enfield's level of precision manufacture.
Title: Re: My New Plan
Post by: AgentX on December 12, 2014, 11:55:58 pm
Finally, I have become capable of wiring things up sorta neatly.

(http://tapatalk.imageshack.com/v2/14/12/12/183cd480f12033318bc8fb4955f4d424.jpg)

(http://tapatalk.imageshack.com/v2/14/12/12/ff7c4f68402c79c1ced8d13fbfe400f7.jpg)
Title: Re: My New Plan
Post by: High On Octane on December 16, 2014, 02:43:18 pm
Hey Agent, didn't you install stainless braided oil lines?  If so, where did you source them?
Title: Re: My New Plan
Post by: AgentX on December 16, 2014, 10:28:41 pm
Yep, I think the pics are a page or two ago.

I used Earl's Speed Seal hoses and fittings.  As I recall, this was one of the few brands of hose ends that had one particular size combo I needed to do it the way I wanted.  You have lots of options with this stuff.  Banjo ends were what I did, but you could do it other ways...straight hose ends, elbows, etc.

You need to drill and tap the oil fittings on the case and head for the appropriate fittings.  I used 10mmx1.25 threaded banjo bolts.
Title: Re: My New Plan
Post by: AgentX on January 04, 2015, 07:50:04 pm

(http://tapatalk.imageshack.com/v2/15/01/04/f460e8a1a47d68c6751422989708d96b.jpg)

Hey, that thing in my driveway resembles a motorcycle now!  Long way to go on the rear brake setup, which is my remaining major project.

(http://tapatalk.imageshack.com/v2/15/01/04/50f017acf80cabe4bf24d62fe554a63b.jpg)

(http://tapatalk.imageshack.com/v2/15/01/04/c4973e9eefd549e874fd5e467cd1db77.jpg)

Wire runs tidied with high-temp split conduit...originally thought it would look ghetto, but even if true, it looks a lot better than anything else I tried, and is so much easier to use...

(http://tapatalk.imageshack.com/v2/15/01/04/3299fa40e7bd48d73981fe80241384d8.jpg)

Bent up the included speedo bracket to attach to my dash.  Better than the fork leg solutions I tried; all I need it for is the odo anyhow.

(http://tapatalk.imageshack.com/v2/15/01/04/ab1d62e7280377d27061eef00b0e5ce1.jpg)

Supertrapp looks cool, but I need a better header fabbed and mounts made.  Header will probably be mild steel, painted black or silver or whatever I can get.


Remaining to do:

Major work to complete:

-Rear brake tab and spacer fabrication, brake assembly and some minor machine work to make bolts and linkages fit
-Exhaust header fab and muffler mounting

Minor but still time-consuming stuff (front to back):

-Re-dish front wheel to center (waiting on a spoke wrench)
-Install fender
-Replace headset cups and dust cover, machine stem nuts to fit
-Install front brake (thankfully complete and bled) and disc
-Speedo light wiring (need some tiny connectors for the 20ga leads)
-Once it arrives, install decomp cable then final install of decomp unit into head
-HT lead coil to plug
-Shock, tank, seat hardware in place for final install
-Chain on
-Toolboxes on
-Chainguard on
-Drain transmission and put in new gasket and plug washer, with some RTV sealant, to stop [negligible] seeping. 


Actually, that list isn't so bad.  Rear brake is the big hurdle.  Exhaust will just be something I pay someone else to do, but I see an ordeal getting the header to seal on the head; shimming and RTV always seem to be involved, regardless of how careful and exact I try to be.

The rest is housekeeping-ish, but working conditions just suck with all the dust and the bugs and terrible lighting I really can't improve on.  Weekends are my big time to work, but have to balance that all with keeping the family in tune too.
Title: Re: My New Plan
Post by: ace.cafe on January 04, 2015, 10:01:34 pm
Definitely coming along!

Beware that the SuperTrapp may be holding back quite a bit of hp.
Title: Re: My New Plan
Post by: AgentX on January 04, 2015, 10:18:04 pm
Definitely coming along!

Beware that the SuperTrapp may be holding back quite a bit of hp.

Really?  I have no experience but bought into the hype (and scored a used can on the super-cheap...)

I also have an Emgo meg I could use.
Title: Re: My New Plan
Post by: ace.cafe on January 04, 2015, 10:58:52 pm
Really?  I have no experience but bought into the hype (and scored a used can on the super-cheap...)

I also have an Emgo meg I could use.
The Emgo is the ticket. We know that one works.

Cut the header length to 31" from one end of the pipe to the other, not including the muffler. Just the header pipe alone is 31"..
Title: Re: My New Plan
Post by: AgentX on January 04, 2015, 11:12:34 pm
The Emgo is the ticket. We know that one works.

Cut the header length to 31" from one end of the pipe to the other, not including the muffler. Just the header pipe alone is 31"..

Especially if I'm going to use the bigger Emgo, I'm likely to have some fitment issues that push the header just a little longer, more like 33-34".  But we'll see. 

I'd most like to use a p-style clamp to mate the header to the muffler and hang that off the stump of the unused stock footpeg support.
Title: Re: My New Plan
Post by: AgentX on January 11, 2015, 09:18:14 pm
Damn.  With the rearsets, I am having a hard time finding a good mount for the muffler, especially the biggr emgo.

I think my choices boil down to:

1.  Remove the centerstand and proceed with mounting in the usual place.  I will gain some "racy" credit but lose a lot of utility...on the most plus-y side, I don't need to do anything wacky to mount the exhaust.

2.  Pull one of the toolboxes off and high-mount the muffler with a custom header.  With a short header, however, that runs into leg interference issues, although pipe wrap makes an easy heat shield.  Right side puts the pipe near the air intake, though, and left side (tracker style...) could heat up the rear brake reservoir some.  And either side pretty much points the exhaust flow straight at the respective shock, although a little bend could create some more calf space while aiming the output outboard of the shock.

I could possibly fit the supertrapp and keep the centerstand, or find a smaller megaphone, too. 


I don't make things easy on myself. Ugh.

Title: Re: My New Plan
Post by: Blltrdr on January 11, 2015, 09:33:59 pm
Damn.  With the rearsets, I am having a hard time finding a good mount for the muffler, especially the biggr emgo.

I think my choices boil down to:

1.  Remove the centerstand and proceed with mounting in the usual place.  I will gain some "racy" credit but lose a lot of utility...on the most plus-y side, I don't need to do anything wacky to mount the exhaust.

2.  Pull one of the toolboxes off and high-mount the muffler with a custom header.  With a short header, however, that runs into leg interference issues, although pipe wrap makes an easy heat shield.  Right side puts the pipe near the air intake, though, and left side (tracker style...) could heat up the rear brake reservoir some.  And either side pretty much points the exhaust flow straight at the respective shock, although a little bend could create some more calf space while aiming the output outboard of the shock.

I could possibly fit the supertrapp and keep the centerstand, or find a smaller megaphone, too. 


I don't make things easy on myself. Ugh.

I would reroute the Ace canister to the left side and run the exhaust high as your suggesting.
Keeping as much of the header heat from the intake is plus.
Title: Re: My New Plan
Post by: AgentX on January 11, 2015, 09:43:23 pm
If I am going with a high exhaust, there is a ton more room on the left side; I think that would be easier and offer more routing options than doing it on the right, without the need to move the intake.
Title: Re: My New Plan
Post by: Blltrdr on January 11, 2015, 10:10:03 pm
My thought is that the exhaust exits head to the right and even if you go to the left side with the exhaust you will still have the hotter air sucking through you're intake. Maybe not a big deal but Tom (Ace) has made reference to this many times.
Title: Re: My New Plan
Post by: AgentX on January 11, 2015, 10:36:19 pm
I think what I am missing is the reason that I would get cooler intake air by running the exhaust on the ri6ght and the air can on the left as opposed to vice versa...seems the same to me either way.  I don't think I am catching something about what you are envisioning.
Title: Re: My New Plan
Post by: AgentX on January 11, 2015, 10:42:52 pm
Also might be a practical use for pipe wrap...much as I dislike the aesthetics, keeping heat from radiating is good for the intake and for my delicate skin, which is averse to burns.
Title: Re: My New Plan
Post by: Blltrdr on January 12, 2015, 12:47:08 am
I think what I am missing is the reason that I would get cooler intake air by running the exhaust on the ri6ght and the air can on the left as opposed to vice versa...seems the same to me either way.  I don't think I am catching something about what you are envisioning.

The exhaust exits on the right side of frame in either in stock configuration or in non stock (left side routing). The heat from the header when exiting is blown back while cruising right in the path of the intake. So as I see it as explained by Tom Lyons is you collect your cooler air on the opposite side of the exhaust for optimal performance benefit. If you were to wrap the exhaust around high to the left side you would now have hot air coming off the exhaust from both sides which would not be optimal for intake air. Wrapping the pipe or ceramic coating the header would probably help for intake and exhaust performance.
Title: Re: My New Plan
Post by: ace.cafe on January 12, 2015, 01:32:42 am
The air filter intake on the Ace Canister is on the bottom for this reason. The hot fins in front of it are above the level of the filter intake.

Title: Re: My New Plan
Post by: Blltrdr on January 12, 2015, 02:38:23 am
The air filter intake on the Ace Canister is on the bottom for this reason. The hot fins in front of it are above the level of the filter intake.

My reference is when you were experimenting with intakes on your bike. You wrote up some pretty lengthy posts explaining the benefits of grabbing the coolest air possible.
Title: Re: My New Plan
Post by: AgentX on January 12, 2015, 06:29:46 am
Yeah, I am not too concerned about theside from which the header exits...wrapped back to the left, it is still shielded from the intake by the bulk of the head and barrel, and Tom's point further eases my mind.  It does raise the issue of dropping the header too low on either side.

 Wrapping it would be a good idea in either case and largely ameliorate concerns.
Title: Re: My New Plan
Post by: AgentX on January 12, 2015, 06:58:20 am
(http://www.shedbuiltbikes.com/wp-content/gallery/enfield/IMG_60661.jpg)

Only existing example I know of.  A few things I would do differently on mine because of the header length requirements and my mid-set pegs, but that is about right.
Title: Re: My New Plan
Post by: ace.cafe on January 12, 2015, 10:10:11 am
My reference is when you were experimenting with intakes on your bike. You wrote up some pretty lengthy posts explaining the benefits of grabbing the coolest air possible.
Cooler air is better.
When I made my ram air airbox, I ducted it to take air from the left side with the duct inlet forward of the engine fins. However with the standard layout with the intake behind the engine, some heated air will enter, and so we take it in lower behind the engine where the temps are slightly cooler.

Moving the canister location requires a longer curved hose which can have potentially negative effects on air flow. We try not to introduce turns in the flow after the plenum. Also, the connector hose on the Ace Canister is a certain length which acts as a tuned pipe like a stack that affects wave tuning of the intake tract.
Title: Re: My New Plan
Post by: AgentX on January 12, 2015, 08:13:34 pm
Tom, what's the rationale about the Supertrapp bottling up HP (I assume by flowing less...?)  I thought with the max number of discs, they were supposed to be super-free-flowing.

Again, I'm going by marketing, so my understanding is limited.
Title: Re: My New Plan
Post by: ace.cafe on January 12, 2015, 08:32:44 pm
Tom, what's the rationale about the Supertrapp bottling up HP (I assume by flowing less...?)  I thought with the max number of discs, they were supposed to be super-free-flowing.

Again, I'm going by marketing, so my understanding is limited.
The discs don't really flow like they imply they do.
In 40 years, I have never heard anyone that was happy with a Supertrapp. They just don't work. It's all marketing and no go.
Title: Re: My New Plan
Post by: AgentX on January 17, 2015, 10:43:09 am
It lives and breathes!  Oil flow is sort of insane.  My daughter wants to know when it will be moving.

Thanks and respect to Tom and Chumma.  This is undoubtedly a far different machine than it was as a little 350.

I will see about a video when I can work the upload from this rather Internet-deprived location.

Title: Re: My New Plan
Post by: ace.cafe on January 17, 2015, 12:08:35 pm
Yes, video!
 ;D
Title: Re: My New Plan
Post by: AgentX on January 17, 2015, 12:57:09 pm
Working on it.  I should probably take a second one with it actually running for a period of time...

Ed:  Here https://www.flickr.com/photos/15217562@N00/16298291281/


It's obviously running rich with the jets set up for break in by Chumma, and I think maybe it's a tad advanced based on some gray smoke spitting from the carb, kickbacks, and skipping at idle.  It won't idle on its own very long, even with the idle speed screw turned all the way in, and I have the mix screw set about a turn out from bottomed.

The tach isn't working despite having power and illumination-need to check the coil lead.  [edit:  got power to the tach, continuity with all wires, and dip switches in the right places...it's quite possible this thing is broken after the pre-install life it's had kicking around 3 continents.  Housing is already cracked and repaired and it's kind of patchwork.  I just ordered a new $50 pedestal-mount Autometer for a simpler wiring setup and cleaner mounting.  Might put it in the same place, might put it lower and out of the way.]

My taper-bearing head cups I was so eager for may not be living up to the job.  There is a rattle I'm feeling during idle, but I'll work through it...worst that happens is the stock loose bearings go back on, which isn't really an issue at all, and solves my steering stem length problem.
Title: Re: My New Plan
Post by: ace.cafe on January 17, 2015, 02:53:00 pm
I'll bet you never thought you'd see oil flow like THAT coming thru a Bullet!
 ;)
Title: Re: My New Plan
Post by: mattsz on January 17, 2015, 03:10:35 pm
Awesome!  But... does that engine have any compression?  The only way I can kick my UCE over like that is if I remove the spark plug...
Title: Re: My New Plan
Post by: ace.cafe on January 17, 2015, 03:17:51 pm
Video requires sign-in.
Can't be viewed by non-members.
Title: Re: My New Plan
Post by: ace.cafe on January 17, 2015, 03:19:34 pm
Awesome!  But... does that engine have any compression?  The only way I can kick my UCE over like that is if I remove the spark plug...
It has more compression than your engine has.
The difference is that it has a working compression release that releases ALL the compression pressure, instead of just a little bit of it like the UCE has on the exhaust cam.
Title: Re: My New Plan
Post by: AgentX on January 17, 2015, 04:28:50 pm
At first kick over it had very little compression; I wasn't using the decomp in the video.  Per Chumma, this is normal as the rings aren't sealing well in the barrel until they wear in a little.  Now I can almost stand on the kicker when it comes up on the comp stroke, and this should get better and better in short order.
Title: Re: My New Plan
Post by: AgentX on January 17, 2015, 04:30:11 pm
Video requires sign-in.
Can't be viewed by non-members.

I made it public on flickr, but you may need to sign in using your yahoo account... Flickr is a yahoo service now.
Title: Re: My New Plan
Post by: High On Octane on January 17, 2015, 04:33:30 pm
I have to know where you got an Autometer tach for $50.  I need one of those.  :)
Title: Re: My New Plan
Post by: AgentX on January 17, 2015, 04:36:05 pm
I have to know where you got an Autometer tach for $50.  I need one of those.  :)

Amazon, or direct from the mfr.  Autogage line, 2.75 or 3.75" options in pedestal mount.
Title: Re: My New Plan
Post by: mattsz on January 17, 2015, 04:50:55 pm
Video requires sign-in.
Can't be viewed by non-members.

First time I tried the link, it opened a new window and flickr asked me to sign in.  I left that window open, and went back to try the link again.  A second window opened and showed me the video.  (http://d26ya5yqg8yyvs.cloudfront.net/ne_nau.gif)

Thanks for the compression info, guys...
Title: Re: My New Plan
Post by: ace.cafe on January 17, 2015, 04:52:25 pm
I made it public on flickr, but you may need to sign in using your yahoo account... Flickr is a yahoo service now.
Okay, I see it now. Came right up on my android.

Anyway, yes the compression needed to seal. That's why it kicked so easy without the decomp.
You need to do a quick tune, and then get it on the road to load the rings for break in. Do not spend time with idling, because it will not bed the rings well without load, and you risk glazing.
Start it up, get it adjusted well enough to hold an idle and warm up, and then get right on the road with some load in accel and decel immediately.
Short rides to avoid overheating. It will get hot fast until it's more broken-in.
Title: Re: My New Plan
Post by: AgentX on January 17, 2015, 07:41:08 pm
So, Tom, give me a hand then, so I don't glaze it with hours of messing around learning my lessons here--it's an unsteady idle, hunting up and down that wants to die off despite the throttle screw being turned completely in, but stays going (unsteadily) with some hand throttle, and kicks back and spits gray smoke occasionally on startup.  It doesn't like to start and needs a bunch of kicks.

I am thinking retarding the timing a shade (Boyer Digital, set up by Chumma when he built the engine) and leaning the idle is the place to start.  Sound like the right plan?

Edit:  This is with the Emgo meg on there.  I have it mounted with the centerstand down, and I'll take the meg off to raise it when it's time to ride, then use the sidestand until I can get the new header made.
Title: Re: My New Plan
Post by: ace.cafe on January 17, 2015, 08:04:10 pm
Too lean.
Try the next size pilot, with the bleed screw 1.5 turns out.
It should need the enricher to start cold, and need it off after about 30-45 seconds.
When it gets nearly warm, use the air bleed screw to find the highest idle speed(either in or out), and then use the idle speed screw to set it to about 1000 rpm.
Then take it out and ride it up and down the street, accelerating and decelerating fairly briskly, but only up to about 3500 rpm max, and decelerate back down using the engine. First ride should be about 10 minutes or less. You can shift thru the gears. Don't overheat.
Title: Re: My New Plan
Post by: AgentX on January 18, 2015, 09:58:58 pm
Tom's pretty much dead on, I'm sure.  After a long series of methodical testing on video for Chumma which yielded nothing, I got it to fire up by the same method I had been using--lots of throttle, no choke, kicking hard.  (Already destroyed my knee rocketing back against the bar...gonna be fun on my run tomorrow...)

It ran super-lean and snapping back at me badly.  You can see the flashes at the carb.  (Air can was removed for the videos to show I had air flow and demonstrate the slide position at rest.)  But when I added choke, it started to run at a hammering high idle.

https://www.youtube.com/watch?v=tiraMZLjmUI

Chumma's going to send me some richer idle jets and a 3-way timing pinion.  One of the concerns is the octane of the gas here, so I'm looking for some additive I can get locally (pure toulene, maybe...)

The fight continues. 

If we were in Jersey, this would have ended long ago with good gas and Chumma and Tom on hand to get it all right from the start...working by proxy across three continents and third-world variables has its disadvantages. Not to mention my own involvement, which probably handicaps the enterprise more than anything else.

Title: Re: My New Plan
Post by: High On Octane on January 18, 2015, 10:38:23 pm
I just posted on do The Ton, but I think your timing is too far advanced.  Retard it 4-5 degrees and try starting it again.
Title: Re: My New Plan
Post by: AgentX on January 18, 2015, 10:45:50 pm
I just posted on do The Ton, but I think your timing is too far advanced.  Retard it 4-5 degrees and try starting it again.

Been through everything from full retard to full advance.  Bubkis.
Title: Re: My New Plan
Post by: Blltrdr on January 19, 2015, 02:49:12 am
Watching your video it reminded me of when I was trying to get my bike going after I installed the Boyer Micro-Digital EI. I remember there were two different setup instructions for the unit and neither seemed to get it just right. I called the Boyer company in England and actually talked with the owner/founder about my situation. He had me work the setting out with one of his tech guys and all was well. Can't remember the setting though since I went back to a points setup a few years back.

Also make sure your gas cap vents properly. I had a problem with the vent on a Hitchcock's 50's style cap that drove me loony till I replaced it with a Emgo knockoff.

Congrats your bike is really coming along and you should have this last bit sorted shortly.
Title: Re: My New Plan
Post by: ace.cafe on January 19, 2015, 12:53:13 pm
I just noticed in the pic that the carb is mounted on a slight downward tilt, and this carries out to the Ace Air Canister also sitting lower than usual.
I recommend trying to straighten that carb mounting angle, so it does not droop like that, even if it means you have to shim the tank up a bit.
That carb needs a straight entry. The downward tilt will affect air flow in an unwanted way, and will cost power.
Title: Re: My New Plan
Post by: AgentX on January 19, 2015, 03:29:18 pm
I don't know what pic in particular you are referring to, but things are pretty tight under the tank; I had to grind some mounting tab to make it fit.  I think it is not a factory tank.  There is also a great deal of interference between the head steady and the choke knob, which I just ground down to relieve.  This may have been affecting the position of the carb.

If the airbox was to sit higher, I would need to shorten the inlet hose to the carb.  At its current length, the air can is in contact with the frame, where the top tube branches into the two side portions. (Adding pic of that.)

In any case, I loosened up the carb without the air can on, reset the hose clamps and remounted the air can (needed to bend my own bracket up).  Hopefully it meets standards, but if not, there is literally nowhere/no way otherwise to mount it all.

Title: Re: My New Plan
Post by: ace.cafe on January 19, 2015, 04:01:35 pm
Ok.
Just so you are aware, that connector hose on the air canister is just a friction fit, and you can move it in or out to adjust length, and even angle to a certain amount.
That might help out with some frame clearance.
Title: Re: My New Plan
Post by: AgentX on January 19, 2015, 04:06:58 pm
Ok.
Just so you are aware, that connector hose on the air canister is just a friction fit, and you can move it in or out to adjust length, and even angle to a certain amount.
That might help out with some frame clearance.

I realized but figured it was intended to be used as a certain length...even if I bottom the hose on the center bolt,I don't think I can raise the position at all. Should I trim it shorter?
Title: Re: My New Plan
Post by: Mike_D on January 19, 2015, 04:23:28 pm
Hey AgentX, I just watched the video for the first time and it reminded me of the first few starts of my Clubman build. 

The first time I was trying to start the bike they were repaving my street and one of the construction workers took a liking to me and my bike (in Brooklyn BTW).  He hung around the whole time saying "come on baby" while I was struggling to start it, fiddling with the timing etc.  It was maddening.

Though I cannot say exactly what the problem is I do know that it took 4-5 starts and small trips around the block to get things to where they should be.  Mine was kicking back just like yours so I kept retarding the timing to the point where it would not start at all.  I ended up with timing a hair advanced from where Chumma had set it when he gave me the engine.

I know that is not super helpful and that you've been through a full retard and advance but try and not get too discouraged and keep at it.  The first 20 miles are the worst, after that things smooth out and pretty soon you'll be having a blast.

The bike looks great by the way.

edit: also, I pretty much never have to use the choke.  I kick over the engine a few times with the ignition off and the enricher on.  Ignition on, choke off, one kick and it goes.
Title: Re: My New Plan
Post by: ace.cafe on January 19, 2015, 04:25:33 pm
I realized but figured it was intended to be used as a certain length...even if I bottom the hose on the center bolt,I don't think I can raise the position at all. Should I trim it shorter?
No, it isn't as critical as the carb/manifold angle.
But if you think you can make a better fit, you can trim it if you want.
Title: Re: My New Plan
Post by: AgentX on January 19, 2015, 04:40:42 pm
Unless you think otherwise, I will drill and do a final bend on this bracket  for this new position.  I had to notch the hose about 5-7mm to get around the center bolt.  Good, or is it better to trim it evenly?
Title: Re: My New Plan
Post by: Blltrdr on January 19, 2015, 04:45:14 pm
Leaving the top cap chrome on the Ace canister can be problematic in direct sunlight. There is a very good chance that sunlight will reflect off generating enough heat to melt your wire sheathing or seat material or something else. Wish I would have thought about that before the bottom of my seat got singed. Just scuffed it up and painted it black to match the canister.
Title: Re: My New Plan
Post by: ace.cafe on January 19, 2015, 04:48:46 pm
That's better.
Notching is fine.

Regarding the chrome lid reflections, they have been painted with a matte "frosted" finish on top for years now. No other incidents have been reported since.
Title: Re: My New Plan
Post by: AgentX on January 19, 2015, 04:49:16 pm
Leaving the top cap chrome on the Ace canister can be problematic in direct sunlight. There is a very good chance that sunlight will reflect off generating enough heat to melt your wire sheathing or seat material or something else. Wish I would have thought about that before the bottom of my seat got singed. Just scuffed it up and painted it black to match the canister.

It has the frosted coating to avoid problems.  In any case, it is pointed at bare aluminum.

I was hoping to have it green to match the body, but there wasn't a chance to spray it.  If I do the headlamp and some other parts in OD later on, I will also do the cap.
Title: Re: My New Plan
Post by: AgentX on January 19, 2015, 05:11:54 pm
OK, that is mounted on there nice and solid-like.

Kicked out at an angle, but that lets me tuck it up higher.  Thanks for the spot. Now if only I could get it to start...  :p

Title: Re: My New Plan
Post by: ace.cafe on January 19, 2015, 05:37:29 pm
Okay, but be aware that if it is not vertical, it will take water into the side of the filter paper element during a rain.
I don't know why yours is so different, but normally they will fit on there vertical in the right place, without fouling any part of the frame.
Title: Re: My New Plan
Post by: Blltrdr on January 19, 2015, 06:08:02 pm
Wouldn't the mount work better if it was installed vertically rather than horizontally. I have my mount attached to the stud on the frame upper gearbox mounts attach. I would think that mounting it sideways would eventually fatigue the metal and end in breakage.
Title: Re: My New Plan
Post by: Chuck D on January 19, 2015, 07:43:18 pm
Mike,
I had symptoms like yours once and it turned out to be a little crud in the pilot jet.
Something to check.
Bike looks great!
Chuck.
Title: Re: My New Plan
Post by: AgentX on January 19, 2015, 08:10:55 pm
Ace:  I think I can rotate the shield a little to help cover the rain side.  Not much of a concern at the moment out here in the Sahel, but rainy season will be upon us.  I don't know why it doesn't fit like it should, but as noted over and over again, nothing's a guaranteed fit on any particular Enfield, right?  The carb is as close to the engine inlet as it can be and the hose is shortened...

Blt:  We'll see.  If the bracket fails to hold up, I'll try a different setup.

Chuck:  Possible-I will be checking the pilot when the richer ones arrive.  Lean mix definitely had something to do with it, per Tom's initial assessment, because when I bottomed the mix screw at Chumma's advice from last night, suddenly I got this:

https://www.youtube.com/watch?v=qciokt-2Y6Q

Open pipe is...well, you can hear it.

Tried it again and got it started, so I finally hit the road.  Was a great blast around the neighborhood!  Feeling the torque was kind of amazing.  Gave it constant on/off throttle at 1500 RPM or so in first/second, got up to third once on a blast across a dirt soccer pitch.  People were covering their ears as I passed.  Hopefully I get the a new header fabbed and the muffler mounted in the coming weekend.


Next bit of good news is that I located a caliper bracket for the rear brake, so fabbing the mounting tab will be much easier to do for the local machine shop.


Things are looking up...!

Title: Re: My New Plan
Post by: Chuck D on January 19, 2015, 10:04:45 pm
Lean, definitely. The way it's hunting is a giveaway.
Regarding the air can. I had to open up the angle of the bracket a fair bit to make the can sit up at the right height. Also had to cut the hose between the carb and the manifold to the width of two hose clamps, Luckily (or by design more likely), the hose from the air can to the carb is long and flexible (I know, that's what she said) to make it all work.
Title: Re: My New Plan
Post by: AgentX on January 19, 2015, 10:21:20 pm
Lean, definitely. The way it's hunting is a giveaway.
Regarding the air can. I had to open up the angle of the bracket a fair bit to make the can sit up at the right height. Also had to cut the hose between the carb and the manifold to exactly the width of two hose clamps, no more. Luckily (or by design more likely), the hose from the air can to the carb is long and flexible (I know, that's what she said) to make it all work.

The carb and the manifold are only two hose clamps apart, and the bracket Ace provides didn't fit to my bike; what is on there is something I bent up from a strip of stock.  The frame is a 1977 Indian army bike, so it's possible there's some variance from the norm here. 

In any case, even with carb stacked as close to the manifold as it can be and with the shortened can-to-carb hose, it still runs into the top tube and needs the angle to allow it to sit as high as it's sitting.  I believe it's intended to nestle right in front of where the top tube branches out under the seat, but that just ain't working here.

We'll see if adding a muffler changes the mix any.  Hoping to have a header made tomorrow or this coming weekend.  We'll see.
Title: Re: My New Plan
Post by: Chuck D on January 19, 2015, 10:37:12 pm
From the last set of pics, it seems you now have a nice straight run from can to carb to head. That's good. My air can doesn't hang perfectly plumb either. The bottom kicks out a little sideways also.
Title: Re: My New Plan
Post by: ace.cafe on January 19, 2015, 10:42:22 pm
Adding any kind of muffler or meg will result in some amount of richening and smoothing.
Having just the short open pipe is exacerbating the issues some.
Title: Re: My New Plan
Post by: AgentX on January 20, 2015, 11:17:26 am
In other problematic news:
http://www.enfieldmotorcycles.com/forum/index.php/topic,21039.0.html
Title: Re: My New Plan
Post by: AgentX on January 20, 2015, 03:26:07 pm
I also took another look at the air can, and got it more vertical and further back, but I am thinking this may pull the carb off-line to the right slightly...
Title: Re: My New Plan
Post by: ace.cafe on January 20, 2015, 03:55:02 pm
I also took another look at the air can, and got it more vertical and further back, but I am thinking this may pull the carb off-line to the right slightly...
The air can angle is less important than the carb/manifold angle.

I noticed that the GT Bonneville bike had that fancy EFI package on it, that didn't fit under the frame well, and it was mounted "droopy" as a result of that. I knew that would be a problem, and wasn't surprised when it didn't even make the Ton.
That changes the angle of air entry in a way that is not good, and it affects the air flow behavior all the way into the cylinder.
It is sort of like "lowering the port" which degrades performance. I was very surprised to see that. I would have modified the frame to avoid that "droop" angle of the throttle body and injector housing.
Title: Re: My New Plan
Post by: AgentX on January 20, 2015, 04:01:05 pm
Gotcha
Title: Re: My New Plan
Post by: AgentX on January 25, 2015, 10:23:21 am
So, yesterday.  Aka "to fab a header."  Or, "Picker's Paradise."

Rented a whole local taxi-van (SoTraMa in the local vernacular) to get the bike to a workshop recommended by a local colleague.

(http://www.dotheton.com/forum/index.php?action=dlattach;topic=54115.0;attach=136349;image)

(http://www.dotheton.com/forum/index.php?action=dlattach;topic=54115.0;attach=136351;image)

(http://www.dotheton.com/forum/index.php?action=dlattach;topic=54115.0;attach=136353;image)

First guys were a bit confounded. 

We ended up having to go look for raw materials.  Turns out that's not really available (although I think we could have tried to find a new exhaust off a hilux to mutilate...). So we ransacked junkyards and bike shops.  I will let the photos speak. 

Exhausts don't grow on trees.  Or do they?

(http://www.dotheton.com/forum/index.php?action=dlattach;topic=54115.0;attach=136355;image)

(http://www.dotheton.com/forum/index.php?action=dlattach;topic=54115.0;attach=136357;image)

(http://www.dotheton.com/forum/index.php?action=dlattach;topic=54115.0;attach=136359;image)

(http://www.dotheton.com/forum/index.php?action=dlattach;topic=54115.0;attach=136361;image)

(http://www.dotheton.com/forum/index.php?action=dlattach;topic=54115.0;attach=136363;image)

(http://www.dotheton.com/forum/index.php?action=dlattach;topic=54115.0;attach=136365;image)

In the end, there was nothing we could find in all that.  Lots of structural pipe, pressed junk from mopeds, etc.  Nothing appropriate for my header.  So we chopped up the stock header to prototype something while I order some decent mild steel bends.

No one could really bend the pipe locally.  There are guys who will sand-fill and heat bend, but their work is even sketchier than what we finally did.  I realize it isn't ideal but it is a prototype for now.  Slotted the pipe, bent into position, and tacked it up, then they booger-welded and ground the shit out of it.

Safety first, boys!  And remember, no ashing your cigarette on your friend's head as he uses the cutting wheel, and all that fave and foot protection is dangerously cumbersome.  But use the fake oakleys to protect your eyes while welding at least half the time, and be sure to share the one set with the other welders so everyone gets a turn.

(http://www.dotheton.com/forum/index.php?action=dlattach;topic=54115.0;attach=136369;image)

(http://www.dotheton.com/forum/index.php?action=dlattach;topic=54115.0;attach=136371;image)

(http://www.dotheton.com/forum/index.php?action=dlattach;topic=54115.0;attach=136373;image)

In the end, it is ugly as hell and probably flows horribly, but is a good prototype.  Think it works OK on the left side, much as I would rather have a low right-side conventional setup.  But with the optimum header length, and the rearsets and center stand in place, it can't be done.

I will be ordering some good steel from Cone engineering and building something better.  Should grab a flex-hone to work the inside of the pipes after local welders do their thing on a more realized header.

Going to add some spring retention at the head if I can, and toss a crush gasket inside if I can get one to fit; I think a Honda CB one I have seen is the correct diameter.

The bare friction fit method of the Enfield sucks!!

(http://tapatalk.imageshack.com/v2/15/01/25/5cdd75069dbea739c69a3e96879449f8.jpg)

(http://tapatalk.imageshack.com/v2/15/01/25/1d3f0a30410560a4ac2205f0febc7d54.jpg)

(http://tapatalk.imageshack.com/v2/15/01/25/0a7063a3284358f2dee12191c880a826.jpg)
Title: Re: My New Plan
Post by: AgentX on January 27, 2015, 08:07:17 am
After all that, I suddenly realized the proper solution to my header issue:  a swept-back header in the conventional position, which should get the muffler clear of the centerstand and the shifter lever.

Simple and easy with a few mandrel bends.  Not as showy as the left-high-side exhaust, which is fine with me, especially for now.  I have been having MC Escher dreams of a twisty front section for the high left header final design, but I can put them to rest for the moment, I think.  Will be ordering the mild steel bends today, I hope.
Title: Re: My New Plan
Post by: ace.cafe on January 27, 2015, 10:12:32 am
I think the swept back is a good idea.
But, that high pipe you made looks good for a scrambler or a woodsman.
Title: Re: My New Plan
Post by: AgentX on January 27, 2015, 10:55:45 am
Well, and a high left-side is flat-tracker correct as well...

I think I have a really good plan for either scenario now.  Might just get enough steel for the high exhaust and see which one works out best in reality, especially once the fabricator's capactity is put to the test.
Title: Re: My New Plan
Post by: mattsz on January 27, 2015, 12:15:58 pm
Rented a whole local taxi-van (SoTraMa in the local vernacular) to get the bike to a workshop recommended by a local colleague.


(http://www.dotheton.com/forum/index.php?action=dlattach;topic=54115.0;attach=136357;image)

(http://www.dotheton.com/forum/index.php?action=dlattach;topic=54115.0;attach=136365;image)

 :o

That is like no "workshop" I've ever seen.  Although, the garage of the "dealer" who floundered his way through my 300-mile service looked pretty close...
Title: Re: My New Plan
Post by: tooseevee on January 27, 2015, 03:52:37 pm
So, yesterday.  Aka "to fab a header."  Or, "Picker's Paradise."

Rented a whole local taxi-van (SoTraMa in the local vernacular) to get the bike to a workshop recommended by a local colleague.

(http://www.dotheton.com/forum/index.php?action=dlattach;topic=54115.0;attach=136349;image)

    How do you get all those pictures to upload when I've lost a whole 1/2 hour of typing text because my ONE picture was too big?

    I guess I'm just a dinosaur & don't get it  :) ;)(http://)
Title: Re: My New Plan
Post by: AgentX on January 27, 2015, 04:21:47 pm
These pics are hosted on another site, and linked to this one via the [img] tag.

I take pics on my phone, upload them to the other site with its application, then just use the URL with the IMG tag.
Title: Re: My New Plan
Post by: motorman2whel on January 27, 2015, 04:52:44 pm
After all that, I suddenly realized the proper solution to my header issue:  a swept-back header in the conventional position, which should get the muffler clear of the centerstand and the shifter lever.

Simple and easy with a few mandrel bends.  Not as showy as the left-high-side exhaust, which is fine with me, especially for now.  I have been having MC Escher dreams of a twisty front section for the high left header final design, but I can put them to rest for the moment, I think.  Will be ordering the mild steel bends today, I hope.
Hi AgentX , I like your idea of a left side high pipe. I was researching building one this past summer for my 500 bullet. You can buy mandrel bend pipes from Summit Racing and piece together a custom pipe. The pre bent pipes are very reasonably priced, although I don't know how much shipping would cost to where you are. Here is a link. Keep up the good work as your Plan is coming together :) . http://www.summitracing.com/search/part-type/exhaust-pipes-individual-bends/outside-diameter-in/1-750-in?N=4294897439%2B4294920630&SortBy=BestKeywordMatch&SortOrder=Ascending&keyword=1%203%2F4%20exhaust%20pipe
Title: Re: My New Plan
Post by: AgentX on January 27, 2015, 05:29:33 pm
Yep, I was trying to source mandrel bends from a place that had everything I needed under one roof.  Ended up going with JEGS, because their house brand is a real bargain, although Summit is another place that often has what I need.  I got three different radius J-bends, which can be used for a lot of different curves with ample straight sections.  I will probably try to keep the left-side routing, as it has grown on me, but it's nice to know I can fall back on a simple and reliable design if required.

When it comes time to do a final pipe in stainless, back in the US with a good fabricator, I'll probably use Cone Engineering (great mufflers!) or Columbia (www.mandrel-bends.com) to source my stuff.

[Shipping is pretty easy for me, as my employer has a scheme for that...]

I was slightly disappointed in the lack of bend radius choices at Cone, though.  I will still probably use one of their straight-thru or max-performance megs on the final product.
Title: Re: My New Plan
Post by: AgentX on January 28, 2015, 07:27:59 am
After the pipe fab, it first failed to start in front of its many new local admirers for about 15 kicks.  Then I found someone had been fiddling with my kill switch--first kick and it came alive.  I went to take it out for a short ride with the pipe, but it died in front of the disappointed crowd.  We announced "out of fuel!" just to end the parade.

Turns out we were right; topped off my campstove bottles at the Shell station on my run this morning, came home, and it kicked right up after two priming kick-throughs (decomp'd) with the choke on.  Off choke after a minute and it ran well.  The idle is turned up to the max possible, and the air screw is still bottomed.

Now I think I am ready to ride it a few more times as-is then begin a tuning session.  I really do think I need to change that pilot jet but Chumma wanted to wait until the pipe had a muffler and the bike had a few more miles on it before altering the jetting.

Compression's a beast.  :)  Really blows your hand back from the pipe.

Right now, the exhaust has the baffle in, but no wrapping.  Chumma runs his cone totally hollow...I am considering throwing a wrap of fiberglass or steel wool on there.
Title: Re: My New Plan
Post by: AgentX on January 28, 2015, 09:32:03 pm
Wow, suddenly things are falling into place.  Little tiny tuning session worked wonders for the idling tonight. 

https://www.youtube.com/watch?v=-CSGuhCWfEY

I risked waking up the daughter and pissing off neighbors for that.  Air screw is 7/8 of a turn out now, so I think I can live with this pilot jet.  Any input based on what you can hear/see from the tach?

Exhaust, I think, will be right-side, swept as severely back as I can make it, with the megaphone also swept up to help clear the centerstand.  Solves a lot of other problems created by left-side routing.
Title: Re: My New Plan
Post by: mattsz on January 28, 2015, 10:06:22 pm
is that tach correct?  If so, in that video you're rolling on the throttle and running your engine up to just below the recommended idle speed of the new unit engines...
Title: Re: My New Plan
Post by: AgentX on January 28, 2015, 10:48:26 pm
Yeah, I wonder if I have the dip switches set wrong so that it's showing half the true count.  It's really the first time I actually looked at it much.  I thought it had to be set at the 4-cyl car setting.

Edit:  Wow, apparently I'm screwed with this tach and a wasted-spark ignition, lol.  No setting will show correct revs. Serves me right for not paying enough attention.

http://www.diygokarts.com/vb/showthread.php?t=10545

Title: Re: My New Plan
Post by: AgentX on January 30, 2015, 06:50:27 pm
Rode to work today!  It's only a mile or two depending on route, so pretty decent for break-in runs.
Title: Re: My New Plan
Post by: ace.cafe on January 30, 2015, 07:55:36 pm
Cool!
How is it feeling?
Title: Re: My New Plan
Post by: AgentX on January 30, 2015, 08:56:49 pm
Feels great!  I am still ironing things out, and with probably less than 3-4 miles total on it, things are still changing every ride.

Lots of guts in first right off the line but seems to flatten out in third--but I'm also still on the very very rich jetting and I think that's the obvious cause of the bogging.  But this thing has instantly changed my expectations of what a bike should be--its worst possible performance is miles above what it was...

Title: Re: My New Plan
Post by: High On Octane on January 30, 2015, 11:22:09 pm
That's awesome Agent X!    :D  I too just started racking a few miles this week, most of which were yesterday after changing the exhaust and timing it.   ;)
Title: Re: My New Plan
Post by: AgentX on January 31, 2015, 10:37:01 pm
My decomp is bad.  Explains some of the issues I was having.  Boooo.  Gonna be another 2-3 weeks off, I think.

And just when I had my first real ride today, to the machine shop to work out a rear brake solution.  Bike was magnificent, and blasting through traffic was like coming home, but Chumma's attributing the leanness and hot running to a slight leak from the decomp.  Looking at the unit, it's easy to see that one side of the seat is wider than the other, and as you rotate the valve with the unit held upside-down, you can see it rising and falling as it rides the cockeyed seat.

Boooooo, I say.  But thankful for great support!
Title: Re: My New Plan
Post by: High On Octane on February 01, 2015, 01:11:45 pm
Some people have removed the decomp and just plugged it.  I don't have decomp on my 700.  ;)
Title: Re: My New Plan
Post by: ERC on February 01, 2015, 01:31:55 pm
That's because the twins don't need them. Much easier to start than the singles.          ERC 
Title: Re: My New Plan
Post by: AgentX on February 01, 2015, 03:52:36 pm
Some people have removed the decomp and just plugged it.  I don't have decomp on my 700.  ;)

Yep, I was looking at options to plug it, at least temporarily while waiting for the new one to come in.  But the problem is that I don't have the right crush washers anyhow.  If I can find them locally, I'll just use the existing decomp and have it tacked closed or something and put it in as a dummy.
Title: Re: My New Plan
Post by: ace.cafe on February 01, 2015, 03:57:48 pm
Can't you just grind/lap it in like a valve in the combustion chamber, until it seals?
Title: Re: My New Plan
Post by: AgentX on February 01, 2015, 04:21:11 pm
The seat needs to be re-cut; it's totally cockeyed.  I can see if the machine shop can do it, since it's probably not too big a job.  But I still need new crush washers, which are an expendable item I don't have on-hand.  (One more thing to add to the "buy lots of these tiny cheap things" checklist)
Title: Re: My New Plan
Post by: ace.cafe on February 01, 2015, 05:23:48 pm
The seat needs to be re-cut; it's totally cockeyed.  I can see if the machine shop can do it, since it's probably not too big a job.  But I still need new crush washers, which are an expendable item I don't have on-hand.  (One more thing to add to the "buy lots of these tiny cheap things" checklist)

Cut it with a cone shaped grinding stone, and then lap it. It's not exactly a precision item anyway.
The crush washers can be taken off of any spark plug. They are the same size.
Title: Re: My New Plan
Post by: AgentX on February 01, 2015, 05:32:23 pm
Worth a try, although if I don't have the right shaped stone for the dremel it might be just as long a wait as ordering a new part.  Dremels and accessories aren't exactly native to west africa. 

I am actually sitting here with a box of old spark plugs as I type this.  Will try some RTV as well.  Even if I can't get the thing to work, I can turn it into a solid plug.

The valve stem itself is a little kinked, visible as you lay it against a straightedge, which may be the reason that the seat ended up off-center in the first place.

Edit:  yeah, it's the warped stem that's the issue.  Grinding the face and lapping won't really change that.  Now, since the decomp is relatively fixed in position by the cable, I may be able to find a way to make it seal up in that one position which should at least hold for a while.
Title: Re: My New Plan
Post by: ace.cafe on February 01, 2015, 05:42:44 pm
Worth a try, although if I don't have the right shaped stone for the dremel it might be just as long a wait as ordering a new part.  Dremels and accessories aren't exactly native to west africa. 

I am actually sitting here with a box of old spark plugs as I type this.  Will try some RTV as well.  Even if I can't get the thing to work, I can turn it into a solid plug.

The valve stem itself is a little kinked, visible as you lay it against a straightedge, which may be the reason that the seat ended up off-center in the first place.
See if you can straighten it out in a vise, or something like that. They do stuff like that in India all the time, to keep these things running.
Title: Re: My New Plan
Post by: AgentX on February 01, 2015, 06:25:57 pm
yep, got my rocks and hammers all ready.  I even work off the ground...
Title: Re: My New Plan
Post by: ace.cafe on February 01, 2015, 06:55:07 pm
yep, got my rocks and hammers all ready.  I even work off the ground...

 ;D
Title: Re: My New Plan
Post by: AgentX on February 01, 2015, 07:06:56 pm
And the stem is straight!!  But now, maybe thanks to my ham-fisted dremeling, I can tell there's a tiny leak when I blow through the bottom while pulling the valve tight.

I can get lapping compound somewhere, I'm sure...maybe the motorpool at work has some.  But in the meantime, is there a home-grown improvised substitute I can grab from the garden or medicine cabinet or something?  (google searches commencing...)

Would polishing compound work...??  I have some sticks of that in three grades.
Title: Re: My New Plan
Post by: AgentX on February 01, 2015, 07:42:19 pm
Pumice hand cleaner seems to be doing a nice job--I'm sure I was stripping off carbon at first, but I think things are starting to come together, literally...
Title: Re: My New Plan
Post by: ace.cafe on February 01, 2015, 07:48:30 pm
Pumice hand cleaner seems to be doing a nice job--I'm sure I was stripping off carbon at first, but I think things are starting to come together, literally...

Necessity is the mother of invention.
 ;D

Sounds like you're nearly done already.
Title: Re: My New Plan
Post by: AgentX on February 01, 2015, 07:58:20 pm
yep, I am!!  This is AWESOME.

I never do properly tomorrow what I can half-ass today...
Title: Re: My New Plan
Post by: AgentX on February 01, 2015, 08:29:10 pm
At the machine shop on Saturday, prior to suspicion of decomp problems...yes, it will have the front fender back on.
Title: Re: My New Plan
Post by: High On Octane on February 01, 2015, 09:13:29 pm
Sweeeeet!!!  Nice save.  :)
Title: Re: My New Plan
Post by: AgentX on February 01, 2015, 10:04:04 pm
Thanks.  It's astonishing how happy this made me, now that the grit is cleaned out with fake Chinese WD-40 and it's ready to install once I can do it in daylight.

Can't face the mosquitos or working in the murky carport tonight.
Title: Re: My New Plan
Post by: AgentX on February 02, 2015, 11:25:14 am
Fun blast into work this morning!

Using the decomp by hand is for the birds.  Cable all the way as far as I'm concerned...  (Didn't have a chance to hook it back up yet.)
Title: Re: My New Plan
Post by: AgentX on February 17, 2015, 08:44:20 pm
Strangely, I am getting used to hand-operating the decomp.

In other news, ummm...is this gonna kill me or be brilliant??

(http://www.dotheton.com/forum/index.php?action=dlattach;topic=54115.0;attach=138337;image)

This is the caliper and a bracket which I worked with a guy for about 8 hours in an African machine shop to make.  Tons of work relieving material from the caliper back to clear the spokes, drilling it for the axle and caliper bolts, and shaping the plate with a hacksaw and a big bench grinder.  Not to mention getting the axle spacers perfect.  Slow going--I thought of heading to work to grab a handheld cordless band saw, but thought better of anything that would cut too much too fast.

So now it's mounted as a test to make sure nothing's interfering, rubbing, or otherwise dangerous.  Not a shake or shimmy or grind from an increasingly tough road test over both pavement and some rough rocks and dirt, so I'll be ready to fill it up and hook the master cyl up to the footpeg sometime in the near future.  Hoping it works as well in operation as it does just hanging there.

Need to come up with the final plan for shaping it and removing (or just speedholing) all the excess metal.  I know it's butt-ugly, but function is where I needed to focus, given the resources at hand and working in a foreign language.

The roosters agreed.

(http://www.dotheton.com/forum/index.php?action=dlattach;topic=54115.0;attach=138338;image)
Title: Re: My New Plan
Post by: ace.cafe on February 17, 2015, 09:03:00 pm
Probably won't kill you.
Might have some oscillations when braking, depending on how thick the sheet metal is.
Title: Re: My New Plan
Post by: AgentX on February 17, 2015, 09:24:39 pm
It's 3/8" 6061 plate; seemed plenty stout compared to most other similar products I could find, like

these (http://www.flattrackaccessories.com/images/P-BrakeAss6hole.jpg)

(http://www.flattrackaccessories.com/images/P-BrakeAss6hole.jpg)

or old dirt bike mount tabs on Ebay...but it also lacks any stiffness that comes from the cast shape of some of the older dirt bike stuff, I'd imagine.
Title: Re: My New Plan
Post by: 1 Thump on February 17, 2015, 09:40:12 pm
There is this one too: http://www.royalenfieldzone.com/view_large.asp?Id=2898
Title: Re: My New Plan
Post by: AgentX on February 17, 2015, 09:44:09 pm
That's where I got my kit from (while I was still in India), but the gear which arrived was even cruder than what's pictured there.  Got it much cheaper than the eBay price they were asking for international buyers.

I lost the (heavy steel) brake mounting tab in my move to Africa, though, and nothing but the master cyl/reservoir, caliper, and hub were useful given my peg set-up.
Title: Re: My New Plan
Post by: AgentX on February 18, 2015, 07:43:17 am
Something like this should work, I think.  Either this, or just round out the existing corners and speedhole it in the areas aft of the caliper.  Ace, any thoughts on which would be stiffer in operation? 


But I'll probably be waiting until everything else is running right before I worry about an essentially aesthetic issue.  A few oz of unsprung weight can wait.

Then again, I'll have the handheld band saw out when we do the exhaust...hmmmm...
Title: Re: My New Plan
Post by: cafeman on February 18, 2015, 12:16:54 pm
Regarding the "brake stay" as it mounts to the swing arm, was that mounting "through-bolt" set-up already there from a previous mod?
Title: Re: My New Plan
Post by: AgentX on February 18, 2015, 01:58:07 pm
Nope, someone in the US did that for me when he did the rearset mounts on the frame.  Ended up not having a chance to finish the job by making a caliper mount bracket before I left.
Title: Re: My New Plan
Post by: ace.cafe on February 18, 2015, 02:34:36 pm
I think it would be stronger of you cut the area behind the caliper angled to the back of the axle, instead of curving it in and back out again. If you are concerned about weight , then drill a lightening hole in the middle. A triangulated perimeter design offers more strength and rigidity.
Title: Re: My New Plan
Post by: AgentX on February 18, 2015, 04:28:08 pm
Cool.  Thanks.  I will just round out the edges and drill it once more important things are done.
Title: Re: My New Plan
Post by: High On Octane on February 19, 2015, 11:37:04 am
If it were mine, I would try doing something like this:

(http://i6.photobucket.com/albums/y217/lethalinj/axbrake1_zps79aa4c7b.jpg) (http://s6.photobucket.com/user/lethalinj/media/axbrake1_zps79aa4c7b.jpg.html)
Title: Re: My New Plan
Post by: AgentX on February 20, 2015, 09:14:46 pm
Damn, 45 miles on a new engine does a number on the oil...

This weekend, head re-torque and hopefully full setup of rear brake master cylinder, reservoir, brake line, and lever linkage.

Next weekend, aiming to get the new exhaust built.


I also need to work out a new front fender option.  Stock unit is now rubbing with my new rims.  (not to mention hitting the exhaust under compression, but that'll go away when I re-route it.)  I thought it was supposed to be a WM2 like the old one, but maybe they sent a WM3...?  Either that or it's just slightly wider.  I dunno.  Didn't used to rub.  Maybe if I can get a fork brace worked out I can trim the existing mounts off and re-use it mounted on the brace.
Title: Re: My New Plan
Post by: AgentX on March 08, 2015, 06:06:58 pm
So. Much. Delay.

About to start on exhaust in a few minutes.  Still waiting on a banjo fitting for brake line setup.

Drilled some holes in the fins to accommodate these exhaust mounting springs, though.  They should help keep the interference-fit header in place.

(http://tapatalk.imageshack.com/v2/15/03/08/4ce0edb812932a2f32563fc3168ac5f1.jpg)(http://tapatalk.imageshack.com/v2/15/03/08/f3ff5b9de40a9614fa2b10d0d3ab92c9.jpg)

Also have a fork brace on the way, which I plan to use for fender mounting too.  We will see if it fits....Fast from the Past frankensteined it together for me.
Title: Re: My New Plan
Post by: AgentX on March 14, 2015, 09:04:41 pm
(http://tapatalk.imageshack.com/v2/15/03/14/6926e5a700923e745a13ac46d6192a20.jpg)

Fork brace fits!  Gonna find a fender to mount to it now.
Title: Re: My New Plan
Post by: ace.cafe on March 14, 2015, 09:18:39 pm
Fits good!
Title: Re: My New Plan
Post by: AgentX on April 10, 2015, 10:46:19 pm
(http://images.tapatalk-cdn.com/15/04/10/aa1f8383e3b638b9165ce2f43f5c6157.jpg)

I am a complete idiot for not spending money on a pre-made header from Hitchcock's.

Working across about two language barriers in a country where the most skilled welders work on the ground wearing sunglasses, while being a complete amateur myself, may not have been the best-thought-out thing I have ever done.  These guys make metal railings and window grills at best.  I know I can't cast stones as I lack both the knowledge and tools to do the work...but that was an ordeal.

That header would have lacked tabs for the exhaust springs and needed an adapter for upsweep, but...not dealing with this would have been priceless.

The guys looked at me like I had a dick growing out of my forehead when I suggested doing the spring tabs a different way, so I rolled with it and let them do it their way...(http://images.tapatalk-cdn.com/15/04/10/83f4ea170c9633520a221d3797ee84e3.jpg)

It is ugly, about two inches longer than optimal for the engine, and not a perfect conduit for hot gas, but I just want to ride the damned thing.

(http://images.tapatalk-cdn.com/15/04/10/a2c735c8fa02c2ecce5ec255e7113c0a.jpg)


Oh: finish options.  Bare, or non-hi-temp paint, or pipe wrap?  Or combo of last two?
Title: Re: My New Plan
Post by: High On Octane on April 10, 2015, 11:06:07 pm
Wrap it, it will hide all the welds.  It may not be the best of fabrication but at least you got a great experience out of the ordeal.  ;)
Title: Re: My New Plan
Post by: AgentX on April 11, 2015, 10:05:21 pm
I wouldn't call it "great" per se, but it was certainly experience.

I wrapped it in a brownish tone fiberglass today and it looks good.  It will probably start corroding away, but in another year and a half I plan on having a custom job welded up in the States.

Pics tomorrow.  I remade the air can bracket, put the rocker back in the newly-helicoiled hole, and sorted some other small things.  Should have it fired up soon...rear disc brake setup possibly finished tomorrow as well, which would put it at a fully-functioning bike.  From there, it is tuning and details.
Title: Re: My New Plan
Post by: High On Octane on April 12, 2015, 12:11:58 pm
By great, I simply meant "one-of-a-kind".  ;)  Glad to hear it's almost ready for the road.  :)
Title: Re: My New Plan
Post by: AgentX on April 12, 2015, 03:30:58 pm
I thought it would be...but suddenly I seem to have no compression.

Edit:  Loss of compression due to resetting the idle screw too low, and starving the cylinder for air.  dum-dum.  Fired up and sounds great!  Back to getting that rear brake set!

MD
Title: Re: My New Plan
Post by: High On Octane on April 12, 2015, 03:59:53 pm
Really?  That's not good.  Maybe something went wronged your decomp mod?
Title: Re: My New Plan
Post by: AgentX on April 12, 2015, 04:01:59 pm
Really?  That's not good.  Maybe something went wronged your decomp mod?

See my edit.  There just wasn't enough air getting into the engine to compress, because I set the idle so low while the carb was off the bike. 
Title: Re: My New Plan
Post by: High On Octane on April 12, 2015, 04:20:30 pm
Oh, cool!  Easy fix.  :)
Title: Re: My New Plan
Post by: AgentX on April 12, 2015, 05:56:12 pm
Oh, cool!  Easy fix.  :)

Yeah, just not the first thing you think of...!
Title: Re: My New Plan
Post by: AgentX on April 12, 2015, 07:55:55 pm
Rear brake is filled and bled...!  Seems to work OK stationary, but we'll have to try it out on the road in the coming week.

Here's that pipe wrap.

(http://images.tapatalk-cdn.com/15/04/12/83c30f702124ea007384854465d4c261.jpg)
Title: Re: My New Plan
Post by: AgentX on April 13, 2015, 08:05:58 am
Successful round-the-block spin this morning!  Tuning is rudimentary, running new jets per Chumma's recommendations, and I think I might reset the Boyer's advance since I know I fudged it a hair advanced before.  Also feels like a little clutch drag I need to dial out...engine slowed then halted at brief pauses two or three times.
Title: Re: My New Plan
Post by: High On Octane on April 13, 2015, 02:58:07 pm
What kind of levers are you using?  I used to get a lot of clutch with the Amal lever, but when I changed them out to dirt bike style levers, the clutch now opens freely and easily.  In fact, it disengages so much I have to engage the clutch a little just to get 1st gear to catch at a stop.
Title: Re: My New Plan
Post by: AgentX on April 13, 2015, 06:36:12 pm
Generic jap bike OEM style.  Worked fine with the stock clutch; I'm sure it's just normal adjustment that needs to be done.
Title: Re: My New Plan
Post by: AgentX on April 14, 2015, 08:16:01 am
Yep.  Was a tad over-advanced.  After a perplexing inability to get it to idle, I retarded it a hair and now it purrs like a very loud, angry kitten eyeballing twenty meters of yarn made of mouse-meat.
Title: Re: My New Plan
Post by: mattsz on April 14, 2015, 10:25:07 am
...now it purrs like a very loud, angry kitten eyeballing twenty meters of yarn made of mouse-meat.

;D  I think a Cheerio just came out of my nose!
Title: Re: My New Plan
Post by: AgentX on April 17, 2015, 12:18:22 am
Home, home on the range...

(http://www.dotheton.com/forum/index.php?action=dlattach;topic=54115.0;attach=142953)

(http://www.dotheton.com/forum/index.php?action=dlattach;topic=54115.0;attach=142955)
Title: Re: My New Plan
Post by: High On Octane on April 17, 2015, 02:07:23 am
Wait a minute...  I didn't know you worked for Blackwater!   ;D    (I guess it's Academi now.)    ;)
Title: Re: My New Plan
Post by: AgentX on April 17, 2015, 06:30:22 pm
Was headed back out there this morning when I washed out...slow low-side on a corner.  Not much damage to me or the bike, but I do need a new brake pedal arm and the primary lower front is pretty gashed up from the slide.  Got some nice rash on my knee through my cotton cargo pants...illustrating the point that jeans just aren't gonna protect you in a fall.

I think I need new tires.  The K70s I have once felt nice and tacky, but despite a lot of tread depth, the compound feels hard and plastic-y.  Had me worried for weeks but I kept thinking that the tires just aren't that old.

But Indian weather, sea transport two ways, a Rhode Island winter outdoors, and Africa may have conspired to render them less-than-optimal.

Gonna get some new Heidenau K34s and give them a shot, I think.  Also considering the Duro 308 (Perelli MT53 copy) but the Heidenaus have had me intrigued for a while, and at this point I want the best grip available.  The AM26s would be great if I rode all pavement, but under local conditions, a block tread is best.  Also considering a proper dual-sport tire, actually.  (Edit:  Perhaps the Heidenau K60 has what I want...not a "tracker" tire at all, but should be perfect for my environment.  Back Stateside I can return to something more classic-dirt-track for the pavement and fireroads.)

Oddly, I'm not that upset...I pretty fatalistic with this machine by now.
Title: Re: My New Plan
Post by: ace.cafe on April 17, 2015, 06:49:27 pm
You could put a track on the rear like a snowmobile!
 ;D
Title: Re: My New Plan
Post by: AgentX on April 17, 2015, 07:41:55 pm
New Ace accessory...?
Title: Re: My New Plan
Post by: mattsz on April 17, 2015, 11:39:48 pm
Glad you and the bike escaped major damage!!!

The K70s I have once felt nice and tacky, but despite a lot of tread depth, the compound feels hard and plastic-y.  Had me worried for weeks but I kept thinking that the tires just aren't that old.

But Indian weather, sea transport two ways, a Rhode Island winter outdoors, and Africa may have conspired to render them less-than-optimal.

Wow - I only get around 4000 miles on a rear K70 - you must not have been riding on them much!
Title: Re: My New Plan
Post by: Blltrdr on April 18, 2015, 04:24:19 am
What is the date stamp on your tires? That might tell you something. As I remember checking the date stamp on my original Avon's, they were already 3-4 years old by the time they rolled the Bullet out of the factory.    :o
Title: Re: My New Plan
Post by: High On Octane on April 18, 2015, 01:02:33 pm
You could put a track on the rear like a snowmobile!
 ;D

New Ace accessory...?


What the heck?  Have you been living in Africa?!   ;D   JK

These things are sick, and I want one something fierce!  It is a kit that basically turns a dirt bike into a upright monorail snowmobile.  Wicked fun, super agile, and seemingly unstoppable in the snow!


https://www.youtube.com/watch?v=PYCT-qWZz44
Title: Re: My New Plan
Post by: AgentX on April 18, 2015, 01:21:33 pm
Glad you and the bike escaped major damage!!!

Wow - I only get around 4000 miles on a rear K70 - you must not have been riding on them much!

It got a year of mostly short commuter work, with a few 50-100 mile weekend jaunts  before it got packed up in summer 2013, and was pretty much in storage in the conditions described since then, so...no, I wasn't.
Title: Re: My New Plan
Post by: AgentX on April 21, 2015, 11:19:51 pm
Got an old bent brake lever arm tweaked straight enough to work for now. 

Re-bled the rear brake and replaced some duct tape I had over the fill hole on the (now dry belt system) primary, using brass mesh like chumma used over the clutch vent holes.

Waiting on Heidenau k34s.   Gotta mount the new tach still.

Thing is starting to look and function like an actual motorcycle!
Title: Re: My New Plan
Post by: AgentX on April 23, 2015, 02:57:33 pm
Wow.  Rear disc brake.  AWESOME.

The stock drum works fine with the stock control setup, but when I switched the peg position, I used Tarozzi pegs and controls, and the leverage factor was changed.  Neither the (modified) short or stock long actuating arm for the brake gave an acceptable combo of power and lever travel.

Breath of fresh air having full control again.
Title: Re: My New Plan
Post by: ace.cafe on April 23, 2015, 03:09:09 pm
Nice!
Rear disc solves a lot of problems, not the least of which is the easier change of final drive ratios with rear sprockets.
Title: Re: My New Plan
Post by: AgentX on April 24, 2015, 11:37:36 am
Nice!
Rear disc solves a lot of problems, not the least of which is the easier change of final drive ratios with rear sprockets.

Alas, I didn't go whole-hog and use a totally new hub with simple sprocket changes, although in retrospect I wish I had.  This is all based on an Indian-made disc conversion kit, with a disc bolted to a slightly modded Enfield rear hub, using the standard cush drive and drum/sprocket.
Title: Re: My New Plan
Post by: AgentX on April 26, 2015, 09:59:38 am
https://youtu.be/uNaU933y2fE

Running after a nice warmup ride.  The muffler is packed so it is a bit more muted than before.

You can see the oil breather mist in the middle of the vid.  Motor still only has 125 or so miles on it from some test commutes and short jaunts.  But that will be increasing now that it is pretty much fully mobile...
Title: Re: My New Plan
Post by: ace.cafe on April 26, 2015, 10:34:50 am
Sounds like it should!
Title: Re: My New Plan
Post by: AgentX on April 26, 2015, 10:50:46 am
Thanks!

I'd recommend the throttle to anyone using the TM32, as well.  It's a Motion Pro "Turbo."  Nice quarter-turn action, not too touchy, just the right amount of pull.

Only thing is getting a throttle cable to fit it.  I've been making my own.  Dunno if the stock would work.
Title: Re: My New Plan
Post by: ace.cafe on April 26, 2015, 11:01:40 am
Thanks!

I'd recommend the throttle to anyone using the TM32, as well.  It's a Motion Pro "Turbo."  Nice quarter-turn action, not too touchy, just the right amount of pull.

Only thing is getting a throttle cable to fit it.  I've been making my own.  Dunno if the stock would work.
Probably the Motion Pro cable that we always use for the TM32 would fit it.
Enfield throttle cable 021-947.
Title: Re: My New Plan
Post by: High On Octane on April 26, 2015, 11:23:23 am
Thanks!

I'd recommend the throttle to anyone using the TM32, as well.  It's a Motion Pro "Turbo."  Nice quarter-turn action, not too touchy, just the right amount of pull.

Only thing is getting a throttle cable to fit it.  I've been making my own.  Dunno if the stock would work.

I'd actually love to have a 1/4 turn throttle!   :D
Title: Re: My New Plan
Post by: AgentX on April 26, 2015, 11:34:00 am
Probably the Motion Pro cable that we always use for the TM32 would fit it.
Enfield throttle cable 021-947.

Hah, I called them about a cable and we went through the custom process...in the end I decided I'd rather learn to make my own!  Geez.  They had a part number all the time?

Scottie, you might look at the "CR competition" model if you want something less 70s-motocrossy...
Title: Re: My New Plan
Post by: ace.cafe on April 26, 2015, 12:51:19 pm
Hah, I called them about a cable and we went through the custom process...in the end I decided I'd rather learn to make my own!  Geez.  They had a part number all the time?

Scottie, you might look at the "CR competition" model if you want something less 70s-motocrossy...

Yes, we have been buying that part number for many years. It even says "Enfield Throttle Cable" right on the label!
Title: Re: My New Plan
Post by: AgentX on April 26, 2015, 03:05:08 pm
Well, to be fair, I did know they had a stock Enfield cable...I just didn't know if it had enough free length to work with the larger carb and throttle drum, plus the extra length this one requires to run around the internal pulley.
Title: Re: My New Plan
Post by: AgentX on May 09, 2015, 09:02:27 pm
Decomp well is stripped.

So that'll be a while.  Shavings have definitively fallen into the chamber, so it can't be fixed in with no matter how carefully I  I am so damned depressed to have to remove the head.  Have to order a helicoil kit.

Actually, it might be easier and far less risky to carry the head back to the states in June and mail it to Ace to get the job done, or find a local machine shop willing to do it where I am on leave.

Or maybe I should just fix the problem with some high explosives and buy myself an SV650.
Title: Re: My New Plan
Post by: Bullet Whisperer on May 09, 2015, 11:48:19 pm
You can cut a thread for an insert without removing the head. Just put it at or near tdc on compression, do the job, then remove the spark plug and stick an airline in, to blow any debris out of the decompressor hole. I did this when I first twin plugged the 350 racer and needed to put an insert in the decompressor side in order to fix a tired thread. There was a moment when a small bit of debris got between a valve and its' seat when trying to push start it and the compression went a bit soft, but as soon as she fired and ran any tiny bits which may have remained were blown right out, with no damage done  ;)
 B.W.
Title: Re: My New Plan
Post by: High On Octane on May 10, 2015, 06:46:45 am
I totally feel your pain X.  I sincerely love the Blackhawk.  I do.  But holy shit some days I just want to kick her over.  Just all the little stupid shit over and over again.  It gets frustrating, but you just have to keep thinking how insanely REwarding it is when she is running tip top and kicking ass.  :)  I love the Enfields and will undoubtedly own a 350 Bullet in the future.  But, I really need to add a Jap bike to the stable for when the Blackhawk is being a twat.
Title: Re: My New Plan
Post by: AgentX on May 10, 2015, 10:42:00 am
You can cut a thread for an insert without removing the head. Just put it at or near tdc on compression, do the job, then remove the spark plug and stick an airline in, to blow any debris out of the decompressor hole. I did this when I first twin plugged the 350 racer and needed to put an insert in the decompressor side in order to fix a tired thread. There was a moment when a small bit of debris got between a valve and its' seat when trying to push start it and the compression went a bit soft, but as soon as she fired and ran any tiny bits which may have remained were blown right out, with no damage done  ;)
 B.W.

Cool, thanks!  The head of the local Toyota dealership is French--i may see him about doing the repair in situ.

I was thinking a helicoil for this application rather than a timesert style due to the flange height of the timesert...thoughts?
Title: Re: My New Plan
Post by: Mr.Mazza on May 10, 2015, 01:10:41 pm
I did exactly the same on my bike, I got a helicoil, put a small bit of rag with grease, TDC the piston. Do repair, remove rag and blow/suck any metal shavings (Piss all) and all was well.
Remember, Alloy is softer than iron, so very little damage if a small peice is left over.
Title: Re: My New Plan
Post by: High On Octane on May 10, 2015, 01:41:26 pm
If you dip the tap in grease it will catch most of the shavings before they even fall in.
Title: Re: My New Plan
Post by: AgentX on May 10, 2015, 03:31:49 pm
Yeah, but I am worried more about the ones I saw fall in already, as I unscrewed the decomp body.
Title: Re: My New Plan
Post by: AgentX on May 13, 2015, 04:20:45 pm
Annnnd, nope.  Although locals say it can be done, the technical manager of the only reputable car dealer here tells me he can't do it in his shop, and that I would be doubleplusunwise to do it in the country unless it was a true emergency.

I'll be in the US soon, so I'll either mail it on ahead or hand-carry it home and let Chumma or Ace do it.  I'm not half-assing something as critical as this.
Title: Re: My New Plan
Post by: AgentX on May 23, 2015, 02:01:30 pm
Head is ready to fly back stateside with me in two weeks...while it is off I have taken the wheels off for new tires and the fork to hunt down a little shudder I have felt from time to time in the front end.  Head bearings seem fine, but I am continuing to explore the issue.

Also trying to get my brake adapter trimmed to fighting weight.  Speedhole locations are an optimistic affectation...I have to get the outside contour right before anything else, and I want to be careful not to make anything too weak.  Probably won't do it at all.

I am working with a hacksaw and a skilsaw, and a small vice not affixed to anything, so it is rough.  I may get out a handheld band saw we have at work, but the only bench grinder I know of is all the way at the machine shop I have used before...big pain to get to.
Title: Re: My New Plan
Post by: ace.cafe on May 23, 2015, 02:43:55 pm
Very difficult conditions to work in.
 :(
Title: Re: My New Plan
Post by: AgentX on May 23, 2015, 05:46:07 pm
Well, on the other side of the coin, fortunate I am headed stateside so soon.  And a carbide cutting bit for the dremel with the router attachment should make short work of trimming the brake tab.  Easy day.  :)

Better people have done more with far less.
Title: Re: My New Plan
Post by: heloego on May 24, 2015, 04:11:01 am
And worse people have done less with far, far more.  ;)

Good on ya, bro! Yer doing great!  8)
Title: Re: My New Plan
Post by: AgentX on May 24, 2015, 11:26:14 pm
Thanks, Helo.  I've certainly put in sweat equity, if that's something.

Today's diagnosis:  (custom aftermarket) headstock bearing cups need a slight re-working to get them totally optimal.

Need a latheing of about .75mm off the inside surface of the cup to 1) stop the inner race of the taper bearing from bottoming against the cup and 2) let the bearing outer race fully seat against the inboard surface of the cup.  Trying to decide whether to tackle locally or try in the US when I'm on vacation.  Local is cheap, and it's a simple job--but a PITA to get accomplished due to travel to the shop.

Once that's done, I can look elsewhere for any remaining front-end issues.  I have tracked some of the clunk-y sensation to the disc brake pads themselves moving slightly back and forth inside the caliper if the bike is rocked with the front brake applied.  Nothing to be done about that, really.

Common issue with mountain bike brakes, so it was easy for me to notice, but there's something else going on at speed I haven't nailed down.  On the plus side, since the rebuild, the bike no longer dives to the left if I take my hands off the bars.
Title: Re: My New Plan
Post by: AgentX on May 24, 2015, 11:36:23 pm
Also in the good news category--who knew?  Toyota dealer in my neighborhood sells octane booster.  Sweet!!
Title: Re: My New Plan
Post by: High On Octane on May 25, 2015, 02:10:34 pm
I thought you had already installed the tapered cup bearings.  ???

Cool about the octane booster.  Any reputable brand, or just what they have?
Title: Re: My New Plan
Post by: AgentX on May 25, 2015, 04:41:32 pm
They were installed.  Now they're uninstalled.

The octane boost comes from the real Toyota dealership so it is at least a consistent source with some chance of quality unlike what I might find occasionally sold out of a plywood shack by the side of the road.
Title: Re: My New Plan
Post by: ace.cafe on May 25, 2015, 05:06:00 pm
They were installed.  Now they're uninstalled.

The octane boost comes from the real Toyota dealership so it is at least a consistent source with some chance of quality unlike what I might find occasionally sold out of a plywood shack by the side of the road.
Just in case you need to know, you can use the paint thinners Xylene or Toluene in amounts up to 10% as octane boosters. These are normally found pretty easily in hardware stores by the gallon. In particular, Toluene is actually what the gasoline companies mix into premium gasoline to raise the octane. But Xylene is basically just as good.
Title: Re: My New Plan
Post by: High On Octane on May 25, 2015, 06:10:52 pm
Just in case you need to know, you can use the paint thinners Xylene or Toluene in amounts up to 10% as octane boosters. These are normally found pretty easily in hardware stores by the gallon. In particular, Toluene is actually what the gasoline companies mix into premium gasoline to raise the octane. But Xylene is basically just as good.

+1  I have used gun wash for octane booster several times, I actually keep a gallon or so on hand now.  It is mostly acetone, toluene and MEK.  Has saved me a couple of times when I have gotten crappy gas.
Title: Re: My New Plan
Post by: AgentX on May 25, 2015, 06:48:42 pm
Yeah, I looked for toulene when I first got here.  I was hoping there was a chemical supplier or something but I didn't find anything.  I should get a pic of what a "hardware store" here is.

And the agony of trying to buy very specific products, especially for purposes not intended by the packaging, cannot be overstated.  Explaining I want paint thinner to put in my gas tank is going to end in tears.  The language and underatanding barriers are too great.
Title: Re: My New Plan
Post by: High On Octane on May 25, 2015, 07:30:16 pm
What is the national language where you are located?  Not that I can help, just curious.
Title: Re: My New Plan
Post by: AgentX on May 25, 2015, 07:34:47 pm
What is the national language where you are located?  Not that I can help, just curious.

French is the colonial language of government, and the most widely-spoken local language is called Bambara.  There are other ethnic languages, but Bambara seems to serve as the trade language.

I have to get by with a meager amount of French, and try to have a local colleague along when dealing with anything technical.
Title: Re: My New Plan
Post by: AgentX on June 30, 2015, 07:20:57 pm
So, after a few weeks in the states, this is done:

(http://images.tapatalk-cdn.com/15/06/30/51f287d9b7d18e02e3cb60e9c3190a58.jpg)

Can't wait to get back and put it on the bike...unfortunately I'm sure a backlog of real work will keep me from having time to do much wrenching upon return.



In other news, this happened, too!  Bike's sitting in Rhode Island and will be brought into running condition in a year or so, I guess.

(http://images.tapatalk-cdn.com/15/06/28/ca013e27ee246cda1e8acee7c3c7bd1b.jpg)
Title: Re: My New Plan
Post by: High On Octane on June 30, 2015, 08:09:08 pm
Is that a Matchless?
Title: Re: My New Plan
Post by: ace.cafe on June 30, 2015, 08:50:40 pm
Is that a Matchless?
Norton Matchless, from when they were owned by the same company. It's a Norton engine, but I think it says Matchless on it. It is the Atlas twin.
Real cool bike. Great for a cafe racer project.
Real major vibrator engine though. Famous for it.
Title: Re: My New Plan
Post by: AgentX on June 30, 2015, 09:44:55 pm
Norton Matchless, from when they were owned by the same company. It's a Norton engine, but I think it says Matchless on it. It is the Atlas twin.
Real cool bike. Great for a cafe racer project.
Real major vibrator engine though. Famous for it.

Yeah, it's a Matchless G-15CS, which from what I understand was substantially the same as the Norton P-11 (Edit:  seems the P11 came along later than this '65 Matchless; this bike's equivalent was the "Norton Scrambler" far as I can tell), which had some pretty cool high pipes as the major external difference besides the badge.   Norton engine with the Matchless frame, which according to what I've read damps the vibrations better than the Featherbed in a fortunate coincidence.
Title: Re: My New Plan
Post by: AgentX on July 06, 2015, 10:02:23 pm
Ok, so the decompressor valve fits fine in the helicoiled hole:

(http://images.tapatalk-cdn.com/15/07/06/416c9ba596d96443d6e05bb519c79bf6.jpg)

The rear brake mounting tab has been prettied up quite a bit:

(http://images.tapatalk-cdn.com/15/07/06/73429a378dac2f3cda727ed7bbb9c29c.jpg)

And the head bearing cups have been reshaped inside (by hand grinder, because a lathe wasn't available when needed).  Races are fully seated, bearings are sitting nicely and turning freely now:

(http://images.tapatalk-cdn.com/15/07/06/67d3b3c5e7ca3381f24b46cb578a75a7.jpg)

Back to Africa tomorrow.  Can't wait to start putting it all back together...we will see when I get that chance.  Lotta work to catch up on before I can play, I fear.
Title: Re: My New Plan
Post by: High On Octane on July 07, 2015, 02:32:07 am
That caliper bracket came out nice.  Glad you could knock all that out while on leave.  :)
Title: Re: My New Plan
Post by: AgentX on July 19, 2015, 11:28:48 pm
So I am waiting for some new head nut washers, because I'm silly and lost some along the way home.  In the meantime, I got the touched-up head bearing cups mounted nicely, after knurling them a little with a center punch and even using a touch of green bearing mount stick on the surfaces.  (I have a bicycle tool for removing them that can be employed if necessary--but I'm hoping they stay in for good, and only bearings possibly need to be swapped out over the life of the bike.)

I also tackled a little re-wiring I was loath to do, but just had to be done.  I am relocating the block connectors for the front end, except the headlamp, under the tank rather than behind the headlight.  The positioning I had was terrible, with the bulky weatherpacks in all the wrong places.  It wasn't just aesthetic; it looked like the wires were being strained/over-flexed during steering. So, a ton of crimp-on butt-splices and heatshrink later, I'm looking at a better scheme laid out on the bike.  Just have to finish the grounds.
Title: Re: My New Plan
Post by: AgentX on July 26, 2015, 01:05:23 pm
Split braided wire sleeving looks cool.  Block connectors now hidden under tank. 

Now for the fork and front end reassembly.  Then the head.  Then maybe in the next week this fucker will run again.

(http://images.tapatalk-cdn.com/15/07/26/bdedbd48acfb825bf4223aeff34ee216.jpg)

(http://images.tapatalk-cdn.com/15/07/26/fbc9e065d910544fa3e328e96e34f19b.jpg)
Title: Re: My New Plan
Post by: High On Octane on July 26, 2015, 02:46:35 pm
Looking good X!  How long are you stateside before you leave for work again?
Title: Re: My New Plan
Post by: AgentX on July 26, 2015, 03:41:22 pm
I am in Mali for another year (w Xmas stateside it seems) then likely in DC on a multi-year assignment.  Probably spend lots of that time deployed in 1-3 month stints tho.
Title: Re: My New Plan
Post by: AgentX on August 14, 2015, 06:06:27 pm
It lives!  And it marked its territory with the breather hose...

(http://images.tapatalk-cdn.com/15/08/14/8a7e257e0cd63e289ca4aa07ff42fe75.jpg)

Must attend to a few brake and chassis tweaks before it rolls...
Title: Re: My New Plan
Post by: AgentX on August 23, 2015, 03:04:02 pm
Had been having some issues with it idling erratically and dying as it became slightly warmed up...frustrating but a combo of new gas (the shit here is pretty skanky and seems to go bad fast, a fresh plug, a quick blow-out of the carb (using a straw, gently), and a timing/valve clearance triple-check seems to have it running well.

https://youtu.be/4IJAE-p1Urc

Got a few more tweaks to make.  Wheels need a final true-up after the local tire guy totally knocked them out of whack by literally throwing them on a concrete floor and attacking them with a massively long tire iron.  Couple of other little things, including some machining work on the stem cone and cap nuts to allow both to fit.

Taper bearing headset seems free of play after having some material ground away and the races seated properly, which is awesome, and the rear caliper bracket looks fantastic.
Title: Re: My New Plan
Post by: AgentX on September 09, 2015, 10:28:39 pm
Got a little ride in, finally!  Grabbed the rest of the Hell's Bureaucrats and hit the road up and around the big hill overlooking town.

Engine ran like a top.  Hope I didn't overwork it, as mileage is still very low, I'd guess like 200 or so.  (Mostly been commuting 1-3 miles to/from work on occasion, and scooting around the block with the daughter on weekends.)  Feels snappy and powerful  Brake and wheel setup still need some work.

(http://i6.photobucket.com/albums/y218/MikesBikes/IMG_1915_zpsasadunl4.jpg)

(http://i6.photobucket.com/albums/y218/MikesBikes/IMG_4823_zpsqc6kc9f1.jpg)

Once everything operational is worked out, I might look at cutting my toolbox width in half and putting them back on the bike.  Going to take a bit of doing with the master cylinder reservoir for the rear.  Might just do a toolbox on one side and a flat aluminum side cover on the other in place of the box.  I can keep some things like a spare plug and fuses under the seat in the tray, but for the tools I'd need to take the wheels off or adjust valves or tighten the steering clamp, even a thinned-up toolbox would be nice.
Title: Re: My New Plan
Post by: AgentX on September 24, 2015, 10:59:59 am
Horrible whining/scraping/ringing noise which had me scared for a bit (left the bike at work for a week until I could give it a once-over after I brought my toolbox) turned out to be a loose primary cover...without dumping ATF all over, due to the dry clutch, the bike failed to let me know it was a little rattly!

Wheels are wonked but my cheapo truing stand just arrived so I can get those smoothed out.

Need to do some machine work to get the steering stem nuts to properly lock down--there's no thread exposed for a locknut right now.

I'm looking at a pretty damned ridable bike now.  Might be time to change the break-in pilot jet for the proper one soon.
Title: Re: My New Plan
Post by: ace.cafe on September 25, 2015, 04:39:44 am
Cool!
 :)
Title: Re: My New Plan
Post by: AgentX on September 25, 2015, 11:24:33 pm
Thanks, Ace.  Hearing and feeling the bike break in to its potential is pretty awesome.

Just put a K&N filter into the canister; the paper one was having obvious issues with the (edit:) WET season and the rain.  Prolly go back to paper once the wet goes away.

Seems to be running fine now-I was having some mixture issues as the paper got worse.
Title: Re: My New Plan
Post by: AgentX on October 02, 2015, 04:52:14 pm
Got back to the machine shop to get the stem cone nut lathed down a little so the top locknut could fit.  The custom cups I had made were taller than stock, and there was no thread to fit the locknut on.  Till now I was just tightening it before every ride...

Two minute job but I had to wait for the lathe guy, so I snapped some hipster bike and machine shots.

(http://images.tapatalk-cdn.com/15/10/02/93985d80743d95459f11ca07a67ac232.jpg)

(http://images.tapatalk-cdn.com/15/10/02/4044c2ce198087f32ea79d1415737dd8.jpg)

(http://images.tapatalk-cdn.com/15/10/02/3e18e78be78a4bd557cfaae904671239.jpg)

(http://images.tapatalk-cdn.com/15/10/02/8f0443064553088a491bcde7dde2867e.jpg)

(Post-holocaust mad max Muppet rooster zombie...)

(http://images.tapatalk-cdn.com/15/10/02/75d0260809ca7886e8bdaca3ce5a2be7.jpg)

(http://images.tapatalk-cdn.com/15/10/02/0f799282d22e53f1ccc7272a5c12f239.jpg)

(http://images.tapatalk-cdn.com/15/10/02/dfdf3d5dc7bb7c03185bc6e8cdc392e9.jpg)
Title: Re: My New Plan
Post by: AgentX on October 11, 2015, 02:04:32 pm
Per Chumma's instructions, swapped the P6 needle jet and 200 main for a P4/185 combo.  Air screw is now about 3/4 of a turn out from bottomed, which worked for an initial start-up and stationary check, but I need to do some riding to get it hot and re-adjust.

Floats a little when dropping back to idle after some mild revs, around the 1200-1300 RPM zone.
Title: Re: My New Plan
Post by: ace.cafe on October 11, 2015, 03:44:47 pm
Sticky advance weights?
Title: Re: My New Plan
Post by: AgentX on October 11, 2015, 04:06:37 pm
It's a Boyer...

Altogether it feels better, more taut and athletic.  It was definitely a little fat before.  Just that little bit of float.  Not much of a problem and we'll see if a little more work with the air screw doesn't cure it.  It's happening with the throttle closed so that's gotta be the jet responsible, no?
Title: Re: My New Plan
Post by: ace.cafe on October 11, 2015, 04:44:07 pm
It's a Boyer...

Altogether it feels better, more taut and athletic.  It was definitely a little fat before.  Just that little bit of float.  Not much of a problem and we'll see if a little more work with the air screw doesn't cure it.  It's happening with the throttle closed so that's gotta be the jet responsible, no?
A little fat during break-in is not too bad. They do better with the jetting Chumma recommended in the warm weather after break-in. It's okay, just keep an eye on the heat.

With the throttle closed, it's either the air screw or there is an air leak.
Only the pilot jet and the air screw are in play with a closed throttle. No other jets are even operating with a closed throttle.
Title: Re: My New Plan
Post by: AgentX on October 11, 2015, 04:49:17 pm
yep, had no worries about the break-in jetting; I know why it was that way, and it ran great even when richer than optimal.

Don't think it's an air leak but I will double-check the hose clams since I did obviously have to take everything apart to get the carb out for the re-jetting.
Title: Re: My New Plan
Post by: AgentX on October 11, 2015, 06:26:51 pm
Got it warm with a little scoot around the neighborhood with the daughter. Re-set the air screw, and now it's fine.
Title: Re: My New Plan
Post by: AgentX on October 12, 2015, 01:12:12 pm
Stuck on a brutally hot firing range waiting for the construction contractor to show...so, more snapshots.

(http://images.tapatalk-cdn.com/15/10/12/b9b86443b4f4cf1fa3c6db7cb48b632d.jpg)

(http://images.tapatalk-cdn.com/15/10/12/e5261f4513ff6746d0c01529c1e94545.jpg)

(http://images.tapatalk-cdn.com/15/10/12/56b6cf57e649ea7722b368f72ddba715.jpg)

(http://images.tapatalk-cdn.com/15/10/12/ecc0cdf523b6584bd294b2501e1307da.jpg)

(http://images.tapatalk-cdn.com/15/10/12/68011c61a9867a203539a6e50f5db086.jpg)

Disc brake setup is good, but I may work up a new linkage for the left-side brake pedal. This one has an inline ball joint which makes up for a lack or precision but I might try to make something which doesn't require that.

Also looking at toolbox/side cover options.   The stock boxes interfere with rider legs/feet due to placement of rearsets.
Title: Re: My New Plan
Post by: High On Octane on October 12, 2015, 01:18:05 pm
Looking real nice!  How did the headset bearing job end up working out for you?
Title: Re: My New Plan
Post by: AgentX on October 12, 2015, 03:00:20 pm
It is working very nicely now.  The first design i tried needed a bit more grinding for clearance; once achieved this worked well except for the taller stack height of the new bearing cups.  This left less exposed thread on the steering stem, leaving nothing for the top locknut to thread down on.  Had to tighten occasionally between short rides.

Two minutes on a lathe turned down the lower cone nut (Thunderbird yoke setup) enough to get the locknut back on and it is copacetic now.

Dunno if it was worth the hassle but it is a nice customish touch, I suppose.
Title: Re: My New Plan
Post by: Adrian II on October 12, 2015, 04:24:34 pm
On a very minor detailing point, you could replace the old rear drum brake's cam spindle housing with a blanking plate, or abolish the old backplate altogether and replace it with a spacer washer of the correct thickness.

A.
Title: Re: My New Plan
Post by: AgentX on October 12, 2015, 05:33:47 pm
On a very minor detailing point, you could replace the old rear drum brake's cam spindle housing with a blanking plate, or abolish the old backplate altogether and replace it with a spacer washer of the correct thickness.

A.

Hah, every time I look at the wheel I'm thinking "When I get around to being annoyed by that, I guess I'll know I have the rest of the bike pretty well sorted out!"

I could drill out the fasteners and pop-rivet a piece of aluminum over it pretty easily, for sure.
Title: Re: My New Plan
Post by: AgentX on October 18, 2015, 01:38:50 pm
Morning spent discovering that my mysterious morass of most current issues are charging-related.  Looks like my fancy, expensive (though obtained at a discount from Hitchcock's used pile) Boyer Powerbox has bitten the dust.  I was apparently charging, but very very little.  After a few recent rides home after dark, the battery was way behind.  Swapped in a new, stock RE ("Swiss") R/R via test leads and everything seemed fine, so I pulled the Powerbox and installed that.

It's possible I just cooked the Powerbox by placing it internal to the seat hump.  Thought it'd get enough airflow, but to be on the safe side, the new R/R is under the entire seat assembly.  It may get occasionally muddy but probably will cool much better regardless.

I'll find a $15 capacitor and wire that in separately.  Not gonna blow cash on a new box.

Oh, and I need to investigate some traces of oil, apparently motor oil, I found in the (dry) primary case.  There was enough to leave a few drips on the ground when I pulled the cover last night looking at the alternator when I was first investigating the electrical problems.  Guessing it migrated up the crankshaft...wonder if that's indicative of anything serious, or just another fact of life with these.  Wouldn't be apparent at all if you were running a wet primary.
Title: Re: My New Plan
Post by: ace.cafe on October 18, 2015, 01:44:41 pm
Capacitor will work fine.
10k uf electrolytic.
Title: Re: My New Plan
Post by: AgentX on October 18, 2015, 01:52:40 pm
Thanks!

Any thoughts on the oil in the primary?  Just a few drips.
Title: Re: My New Plan
Post by: ace.cafe on October 18, 2015, 08:37:53 pm
Thanks!

Any thoughts on the oil in the primary?  Just a few drips.

To fix it, you have to pull the primary and pierce the seal and pull the seal out with a body repair dent puller, or similar puller, by screwing the end into the hole that you pierced thru the seal, and using the slide hammer action to pull out the seal.

If you are not too concerned about it, you could leave it alone, or drill a little drain hole in the bottom of your dry primary, and let it drip out.
Title: Re: My New Plan
Post by: AgentX on October 18, 2015, 09:23:56 pm
Meh, I'll wait till I'm back in the States.  I'll be taking it apart to adjust base gaskets and I'll do anything vaguely major at that point, hopefully in concert with Chumma.

Just wanted to make sure it was likely a seal problem, and not a bearing about to die or a case cracking or something.

There's a drain hole in the primary already...I made it while riding through some tight rocks.  Punched a jagged hole in the case at the front/bottom, so I just dremeled it clean and fixed a bit of mesh screen in there.

Edit:  Capacitor is on its way, too.  10000uf/25v electrolytic.  Screw terminal.
Title: Re: My New Plan
Post by: AgentX on October 27, 2015, 11:21:16 pm
135-140 on the compression tester now, still under 300 miles.  (no really long rides yet; hope for an hour or two out this weekend.  Mostly been back and forth to work and a few trips to the machine shop about 6 miles away.)  Higher than Chumma had actually anticipated, but I'm still not getting ping, so...awesome!  Guess the rings and bore are happy with each other.  I've certainly been doing my best to keep the rings loaded and working hard while the bike's in motion.

Engine is pulling like a train and is pretty happy at higher revs.  Getting first-kick starts in the morning after a few priming kick-throughs.

Electrical is doing fine and questions/uncertainties about things are kind of dying off.  The tires need a remount and balancing, I guess.  Looking to restore the toolboxes if I can narrow the width of them.  (Someone here did that already so there's a good thread with instructions.)  May just rig up some side covers if that doesn't work, and find a different spot to carry a tool roll or something.
Title: Re: My New Plan
Post by: AgentX on November 06, 2015, 10:13:27 pm
Hm, capacitor can run the bike sans battery once started, but the bike just won't start without the battery.  It did so with the Powerbox.

Got a "New Sprague Powerlytic 18000 uF 25 VDC Electrolytic Capacitor" off eBay and thought that'd work.  Did I go overboard and get something too big?  (18 vs 10k uF?)  Does it need to be any specific place in the system?  I tried both between the reg/rect and battery, and between the battery and the rest of the system.
Title: Re: My New Plan
Post by: ace.cafe on November 06, 2015, 10:16:55 pm
It needs to go right where the battery used to be. Connect the + battery cable to the + lead on the capacitor, and the - battery cable to the - lead on the capacitor, and you should be in business. If you want to keep the battery in there, then connect the capacitor across the battery terminals, observing polarity as I previously mentioned.
Title: Re: My New Plan
Post by: AgentX on November 06, 2015, 10:19:23 pm
Grrr.  Tried putting it right there already.  Wouldn't start.  Then I put the battery back in with the cap across the battery leads as described, started the bike, and removed the battery from the system (just had it hooked in via alligator clip test leads) and the bike continued to run without missing a beat.
Title: Re: My New Plan
Post by: ace.cafe on November 07, 2015, 09:57:58 am
Theoretically,  it should need one kick to charge the cap, and then it should start .
However,  with a Boyer there could be something else involved.
Contact Boyer and ask them.
Title: Re: My New Plan
Post by: AgentX on February 06, 2016, 07:52:48 pm
So it's been running pretty damned well lately.  Rattles and pings all sorted out.  Got the kydex cover on the air filter, but it's not very neatly done; might try to dremel it some to make it less horrific-looking.  I need a new speedometer, because this one is totally busted; must have happened when my guards knocked it over early on.  Might go for a digital unit, might just grab another mini job off Dennis Kirk or something.

Wheels and tires are the major remaining issue; there's something out of balance/true, but it doesn't affect me under 60mph, and I rarely get over that in town.  Sucks for longer pavement trips I've been trying tho.  I also need better gas, but unless I'm truly being an asshole, it won't ping on me.  Air screw or jetting may need changing due to cooler weather--won't start first-kick anymore, but I'll get that sorted.

Got a new camera so I took some vanity pics as the sun was setting.  Didn't have time to run them through Lightroom or anything, but they seem pretty good out of the raw converter:

(http://i6.photobucket.com/albums/y218/MikesBikes/SDIM0090_zpsbkzmrdje.jpg)

(http://i6.photobucket.com/albums/y218/MikesBikes/SDIM0080_zpswhtbsfwl.jpg)

(http://i6.photobucket.com/albums/y218/MikesBikes/SDIM0077_zpsghvvn3wl.jpg)

(http://i6.photobucket.com/albums/y218/MikesBikes/SDIM0053_zpsiztivuy6.jpg)

(http://i6.photobucket.com/albums/y218/MikesBikes/SDIM0095_zpsqsq1wd6x.jpg)

(http://i6.photobucket.com/albums/y218/MikesBikes/SDIM0068_zpszlax2kx4.jpg)

(http://i6.photobucket.com/albums/y218/MikesBikes/SDIM0094_zpsdunz2ipd.jpg)

(http://i6.photobucket.com/albums/y218/MikesBikes/SDIM0089_zpsaxjks159.jpg)

(http://i6.photobucket.com/albums/y218/MikesBikes/SDIM0070_zpsuavxdrt2.jpg)

(http://i6.photobucket.com/albums/y218/MikesBikes/SDIM0078_zpsghvasbnf.jpg)

(http://i6.photobucket.com/albums/y218/MikesBikes/SDIM0069_zpsuvedwetj.jpg)

(http://i6.photobucket.com/albums/y218/MikesBikes/SDIM0063_zpsmq01i1a4.jpg)

(http://i6.photobucket.com/albums/y218/MikesBikes/SDIM0062_zpskvplnucr.jpg)

(http://i6.photobucket.com/albums/y218/MikesBikes/SDIM0064_zpsuj73mgpu.jpg)

(http://i6.photobucket.com/albums/y218/MikesBikes/SDIM0066_zpsj4ri7kuv.jpg)
Title: Re: My New Plan
Post by: Chuck D on February 06, 2016, 08:34:37 pm
Lookin' good! 8)
Title: Re: My New Plan
Post by: ace.cafe on February 06, 2016, 09:44:57 pm
Got that "flat tracker" look!
 :)
Title: Re: My New Plan
Post by: AgentX on February 06, 2016, 10:23:59 pm
Got that "flat tracker" look!
 :)

Thanks, guys--I do want to add some side covers, and have some kydex on hand I'll use to give it a try.  Probably mold up a little master cylinder cover with it, too, trying to keep the mud and dust from collecting up near the boot around the shaft.

Will need a place to put tools behind the eventual side covers.  It's too bad the peg positioning prohibits use of the toolboxes, although I suppose I could get them cut, trimmed, and re-welded to give them a narrow enough profile to go back on...
Title: Re: My New Plan
Post by: High On Octane on February 06, 2016, 10:48:20 pm
Bike is looking great!  Always enjoy reading your posts.  :D
Title: Re: My New Plan
Post by: mattsz on February 06, 2016, 10:52:35 pm
Sweet!

Keeping an eye on that air filter?  ;)
Title: Re: My New Plan
Post by: AgentX on February 21, 2018, 09:55:45 pm
Been a while, but I've had it in the US for over a year and it's finally running like a top.  Gave it a shakedown trip of about two weeks to a training site a few hours away, involving a lot of backroad daily driving to and from my hotel and the site-to-home.  Last few weeks of wildly varying temps have made starting a bit of an ordeal at times, but largely it's one or two kicks and going.

Couple of things had been contributing to a high-speed chassis weave, but that's largely ironed out.  I took the tacho off when it started acting funny...may or may not put the recommended tried-and-true VDO on.

One pic of it with the dirt track bars here, and two with the clubmans I just installed as an experiment.  We'll see if I end up liking the lower riding position or not as the weather warms up and I can hit some twisties.  Right now, the little tracker headlamp makes it look like a squished up pug, and the too-long cables are apparent, but it's an ergonomic exercise, not aesthetic. (also accounting for the mixed mirrors...just trying out what works best...)

If it stays with the low bars, I foresee addition of a larger headlight bucket, flyscreen, nose-bowl fairing, or maybe even a Rickman/Avon style half fairing someday.
Title: Re: My New Plan
Post by: High On Octane on February 22, 2018, 01:47:28 am
Awesome!  Can't believe it's been almost exactly 2 years since you've posted on this thread.  Glad to see and hear things are coming together for you.

I'm currently all in on a full engine rebuild for the Blackhawk.  It's been an interesting ordeal to say the least.