parts update

It's been a long time since I have posted so I shall write about the parts I've aquired since there is little actual build progress. I scored a lightened crankshaft at a swap some time ago, I have had it balanced and blueprinted by Countryside Cycle Service in Tallahassee Fl. I am happy with Johns work and recommend him for any British machine work. I also have aquired a set of Invader 5 spoke wheels to roll on. A customer of mine was cool enough to buy me a clutch basket as a thank you for the work I have done for him. All I need now to compete the engine is a charging system and I am ready to assemble the engine.

Skin and Bones A Rollin'

Skin and bones meaning empty cases and wheels attached so it may stand on it's own. The bike is still completely torn down, but today I have a rolling chassis.

Black and Bouncy

Two wonderful adjectives when pertaining to my front end or my wife's luscious boobs. Both of them make me smile and tingle with delight. BOOING! I have sold the abandoned Bandit project and moved on. The sale of PB and Dos provided the windfall of money that brought the new parts home. I am speaking of the DNA +4 Springer Front Fork Assembly that will suspend and steer the chopper. I have purchased a major piece of the puzzle and it feels good.

I still retain the front end that came with the motorcycle. In my eyes, all it is good for at this point is rolling around other chassis. Years of sitting outside ruined an already too long front clip. A rigid front end that would snap like a twig if ridden upon.

I had cleared the workbench the night before. Upon pulling into the garage mere seconds passed before the box was out of the back seat of the truck and lie emptied upon the bench. Like a kid on his birthday I unwrapped the fork and set aside the small pieces. Deftly I removed the top nut, top tree, and bearing nut and set them down on the stand. The forks weigh more than the empty frame does. This is important because the attached chassis is longer than the work stand. I had to hold the fork in place with one hand and set the top with the other. This took a little time as I have no intention of scratching it. Fortunately my son was nearby to steady the back of the frame as finished fastening the fork down. The hands free, step back look was impressive.

Beholding the line I was after, I knew I had chosen the right length fork. With the frame at a level stance, the old front axle sat lower than the bottom frame rail. This kicked the bike at an uphill racer angle. A classic chopper line without a doubt, but it's also a huge factor as to why choppers handle so poorly. I like mine long and low. The frame will remain much more parallel to the ground with the springer. The frame has a 38 deg. rake so the front still sticks out, I have improved the geometry of the bike. Lower Center of Gravity (COG) and better front to back weight distribution. Top end oiling will be less of a problem with the engine sitting flat as well.

Now I need wheels.

Ponderisms

Tonight's thoughts are not build related. I simply felt the need to sit down and prattle. Often I have said that gear is always cheaper than hospital bills. Sadly this was proven to be true today. A close associates mother suffered a no gear accident today. She suffered head trauma and a broken arm upon initial report.

I am a strong proponent of wearing safety gear while riding. Reduce the possibility of injury is objective of wearing purpose built gear. I am not going to comment on how people operate (drive, ride) their vehicles. Not going off on that tirade tonight. People drive enclosed vehicles, cages from here on out, with an exoskeleton all around them to provide protection from bodily harm. Riding a motorcycle there is just you and the machine. No barrier to the elements. Those who almost get it drive convertibles. Bodily harm while riding is guaranteed happen if a motorcycle is halted abruptly in an accidental fashion. As one who rides for the union of man and machine, safety gear is essential for my confidence in the saddle. I have crashed and bruised. You ain't a biker unless you limp. Point is, I love motorcycling enough to get back up and ride again. A helmet has saved me from any kind of head trauma on two different occasions, my Phoenix jacket saved my back from a crippling injury. Regardless of temperature, I wear a padded jacket, helmet, and gloves every time I turn the key and straddle a bike.

What blows my mind are the varied mentalities against taking proper precautions. Know this inherent truth about operating any motor vehicle: Machines of greater mass and power than the operator are deadly if mishandled. Operator Error is the root cause of all accidents. Mechanical failures caused by lack of maintenance is still operator error. Rare is the occurrence of a genuine defect in the vehicle which caused the accident. Manufacturer recall campaigns generally negate the possibility. In short, vehicles don't fuck up, people do.

Four wheels to move the body, two wheels move the soul. I wish to minimise the damage to my body in the event of an accident. Another phrase I am known to say: There are those who have crashed, there are those who will crash, and those who have, may go down again. Not a pleasant thought, but it is true. Crashing sucks but walking away in disgust is better than being carried away in an ambulance. I do not ride in fear. I am not fearless. I do understand my vehicle and the risks of operating it. I accept the fact that I could perish every time I ride. Miyamoto Musashi described the way of the warrior and the "resolute acceptance of death." He stated the death is inevitable and could occur at any moment, regardless of present activity. Knowing this, the sage lives each moment to its fullest and embraces all that life offers. Much of what we do requires special or specific equipment. Preparation of food is an example relevant to everyone unless you're a freak who eats only leaves off live plants. One needs proper equipment to prepare and consume food. One can ride a bike with only the clothes on their back, but it is kind of like cooking bare handed over a campfire. All the stock in your kitchen is worth a few thousand dollars. Why do people find it so hard to throw down a few hundred dollars on equipment which could prevent severe injury or death.

DeRustifed Destiny

Friday the 8th of Febuary, the day which preceeded today, marked long awaited progress in the build. The daily phone call from my son became atypical when he informed me a package had arrived. BOING! The remainder of the workday passed quickly and soon the aquisition was in my hands.
I have been searching for a crankshaft pinion tool. I was willing to settle for someone who owned the right one. Persistance pays off as I won the bid on ebay. For less than fifty bucks I scored the right tool for the job. Going prices I have seen during the wait ranged from 60-100 and the local availibility was none.
Once home last night I came in the house and greeted the family. There on out I was all over the package like a hungry dog. I have a rhetorical question: What is it with ebay sellers who ship their products filthy as hell? I have been satisfied with the all items I aquired because they filled the need. A few of my purchases have shown up dirty as hell, the most recent included. Only fitting that an old iron tool from foggy old England should arrive coated in rust. Safe to venture into the thought this puller sat untouched in a musty wooden toolbox for years. I spent five miniutes and a dozen paper towels cleaning it before adjourning to the garage. Rag in hand and 6-in-1 spray on the threads, I spun the driver end to end and wiped the newly released grime from it. I was gross, no two ways about it. Damp rust which caked off like nasty brown mud. Befitting to the way I found the engine, hideous chud.
Clean and Lubed the black iron puller began to warm in my hands. Molecules awakened as their purpose realized once again. I locked the connecting rods and installed the puller on the crankshaft pinion. Experience has taught me not to bull rush into press fit pieces; I loaded and unloaded the puller a few times before getting the drive that pulled the gear from the end of the crankshaft. Success was mine. I set the tools down and went in the house to be with my family.

Taking it in

Most of this project is being sourced through Ebay. The latest aquisition is a single carb intake manifold. The piece and shipping cost 23 bucks, an average going price. It arrived half polished with good studs. I need to polish the rest of it before it goes on the bike. The first thing I did was to port it. I have chosen to use a single as opposed to duals for cost and simplicity. The port job may seem to be a conflict of interest, but I want to get the most of it. All who have built engines know that airflow is everything. Now I have something to stay busy with until more funds free up and more parts are in hand.

Shiny Alu-mini-um

I have called it tin but there is a difference. Tin is generally a term used for the sheetmetal. Fenders, tanks, electrical boxes and side covers. Chassis parts. Engine covers are made of alu-mini-um. Say it like the English as it is an English bike. I have invested about 20 hours into polishing the rocker boxes. Hand finished by file and sandpaper. I left a few imperfections on purpose, a 40 year old chopper should not be perfect. Leave the surcigially sterile bikes to the posers who can afford 50 grand for one.
The engine side covers were relatively easy to clean and resore a nice finish. The rocker boxes required some time and greater effort due to one mistake. A Dremel Tool shoud carry the same warning as a hammer. If it did not go together with a hammer, don't take it apart with one. One removed, I foolishly loaded a sanding disc on the grinder and went to town removing the years of corrosion. I added quite a few low spots and nicks the took considerable effort to remove. One step foward and two steps back.
Step one. File down the obvious blemishes and blend the surface
Step two. 180 Grit wet sand the file marks
Step three. 240 grit until the 180 scratches vanish
Step four. 400 grit and see all the spots that were missed now that the surface is mostly uniform
Step Five. Go back to the files and start over.
Steps 6-10. Repeat 1-5
Step 11. 600 under a dribbling faucet until the grey filings cease.
Steps 12-14. 800 1000 1200, each time the filings become finer and the scratches become smaller. The metal lightenes in colour with each step.
Step 15. Cr1 Rouge on the buffing wheel. Now I have paid enough pennance and get to use power tools again.
Step 16. Change wheels on the bench grinder and switch to a jewelers rouge for a near final polish.
Step 17. Wipe it down thouroughly and apply a polish/sealer.

For those who seek a mirror shine or a chrome like finish, wet sand with a 1500 and 2000 before using a buffing wheel. Not for me. I prefer some petina and the character it brings.