Tins and Brakes

I sorted out the rear brake, which took me longer than I expected.  It was a bit like one of those bar puzzles made of nails.  I also mocked up the fenders and tank and tweaked them here and there.  I'm going to pick a painter and send them out in a week or so, so I wanted to make sure everything fit reasonably.

Roller!

I finished shimming, greasing and installing the wheel bearings.  It's all pretty straight forward.  I made a tool (a length of copper pipe) to keep the bearing stack together, heated the hub and slipped the stacks in.  I've got the newer wheel nuts with the rubber seals, so I replaced the seals.  I also swapped out the old inner felt seals with rubber ones from Benchmark Works.

 I ended up not replacing the wheel bearings - they looked almost new.  I just cleaned them with kerosene and brake cleaner and repacked them. Late last night I  realized I had put all of the top hat spacers in wrong on both swing arms, so I went out into the garage in my pj's and pulled the swing arms and fixed them.  Luckily, I didn't need to replace the seals.

I also installed the center stand and did a video about installing kickstand springs:

Tomorrow I'll fit the fenders and tank just for fun and also set up at least the rear brake if not the front as well.

The Final Drive Is Done

I popped open the final drive and nothing was sketchy - it looked good to my untrained eyes.  I was afraid I'd find rust, chipped gears, etc. While I was in there I replaced the cover gasket and the ring gear seal.   Don't forget to protect the new seal with a Coke can or something when you put the cover back on.

Heat is the key to getting these things open and then back together.  I heated the cover in the oven and installed it twice, but the ring gear bearing still didn't seat right either time.  Finally, I took the combined advice of Vech and Duane Ausherman and put the whole final drive in the oven for an hour at 200* and then tapped both gear shafts and gave it a couple good thumps with the ring gear facing down.  That settled everything.

I've still got some Honda moly 60 paste from my last shaft drive bike, so I coated the wheel splines with that.

I hit the final drive with some sand paper, grit infused nylon wheels with some Neverdull and then finished off with some Scotchbrite pads and Flitz polish.  I also got new polished stainless swingarm and drive plugs.

Next up is to get some wheels on this thing!

Beginning the Reassebly

Because I know my engine won't be ready soon, I've started assembly of the roller.  The front end is all sorted and on, the seat is on, and the rear shocks and swing arm are on. Like I did with the front shocks, I rebuilt the rears.  Other than to adjust the rear swingarm once the engine is in, I won't have to touch any of that stuff again.

A metric thread file came in really handy for the neck threads and front axle threads.

The wheels are pretty much sorted, I just have to shim  the rear bearing stack a little bit.  I got some shims from Duane Asherman.

I may put the front wheel on this weekend, but before I put on the rear, I want to dig inside the final drive a bit and see what I see (hopefully nothing bad!)  That'll be the last major operation on the bike until I get the engine back.

I thought using the BMW grease fittings would be problematic, but it was super easy with a decent chainsaw greaser. For the front, I did use Duane's tip of wrapping a piece of rope around the left side to keep the grease in.

I also got a good deal on a used 20mm x 1.5 tap to clean out the threads on the frame for the rear swingarm pins.

I replaced both sets of swingarm bearings which should have been pretty straight forward, but as is usual for me, I spent far more time fixing screw-ups than actually progressing.  I somehow thought it would be a good idea to use the old race to set the new race in place in the rear swingarm.  It worked, but the old race got stuck in the swingarm too and it took me a good hour to get it back out without damaging the new race underneath! I also destroyed two seals trying to seat them in place.  I got some new ones (as well as a set of extras) from Hans at Hucky's Spares.  These went in with no problem, so I have to wonder if my first set (which came with the project) were too big.  I really like dealing with Hans, it's very old school since you order through email and he gives you a discount if you mail him a check.

Like I said, next up will be the final drive, then I can complete the roller.

Clean Carbs!

I cleaned up and rebuilt my 38mm Bings and made my wife video it.  She's a sport.

I talked to Tom Cutter, and my engine likely won't be done for this season, so I think I'll install the swingarm and head bearings and put the bike together as a roller.  Then I can just wedge the engine in when I get it and finish the wiring.

More Stuff Cleaned Up

I've been spending my time cleaning and polishing (especially stainless bolts) while I wait for the engine to be done.  I love freshly polished aluminum against gloss black - it looks so clean.  I find it very satisfying when parts go from chipped, dirty and dull to fresh and bright.  I don't polish my metals to mirror shine - I'm too lazy for one thing - but I also like the warm glow created by less polishing.

I mentioned that instead of a turn signal indicator, I'm using that hole in the headlight bucket for my electric start button.  I tried to find a button that mimicked the original indicator.  Ridiculously, I think the thing I'm most proud of is getting the button to light up when I push it.  Originally I wasn't going to bother, but I think it looks really cool!

I placed the last of my big parts orders - I'll probably need odds and ends, but I shouldn't need anything else major.  I still need to clean the carbs, but then once the engine is back, it'll be assembly and wiring.  Paint won't come 'till the winter though (I think I might rattle can it for right now).

One other odd thing - I bought this project basically as a basket case bitsa bike, so I don't know how much of the 50/2 parts started life together.  What I do know is that several of the parts, including the brake linkage, steering damper, and various smaller pieces, were once painted metallic blue.  That would have been a bike to see!

Back from Powder Coat and Pipes!

I picked up everything from the powder coater and it's good.  I actually had to take back the frame and both swing arms to have them redone due to some bubbling, but now everything back.

Also, Tom from Epco came through with my stainless conversion headers - I ordered them about two and a half years ago and paid for time last September, but now I've got them.  They're quite nice too.  I'm still waiting on my stainless mufflers though.

Once I get the engine back, I can start assembly! Even if I don't have the mufflers, I've got others I can throw on in the meantime.

New mounts and blasting

Saturday morning I decided to redo the coil and relay mounts - this time I did brackets instead of bungs.  I felt like there wasn't enough clearance under the tank when the coil was mounted horizontally - the wire rubbers were rubbing the tank.  The relays are bundled together now which I think is tidier.

Today, I media blasted - I went through 120 lbs of media - mostly coal slag from Tractor Supply, which is nice and cheap.  Unfortunately I didn't finish as I ran out of media.  I didn't get to the frame or the rear swing arm, and I didn't finish the front forks.  But everything else is done.  I'll ask the powder coater to finish the rest.  I'm going to use Chester County Coatings in Honeybrook, Pa. on my brother's recommendation.

I always think it will be economical to do my own blasting, but I forget what a huge pain in the ass it is. A few little pieces is fine, but most of a bike sucks.  Balancing the time, hassle, and supply cost vs paying someone to do it - I vote pay someone else.  That said, I do like the intimacy that the process affords - each sweep uncovering blemishes, cast marks, and serial numbers - it's stuff I'd never see if I didn't strip the parts myself.

I really like Eastwood - I think their stuff is a good balance of quality and price.  Growing up, they had a store in Frazer, Pa that I loved to go to.  It's closed, Pottstown isn't that far away.  For blasting, I've got both their 100lb blasting pot and their cheapy siphon gun.  I much prefer the little gun.  You can make one of these pretty easily with just an air gun attachment (my kids gave me this one for x-mas).

Once the coating is done and the engine is done, it will be time to assemble and wire.  Painting the tins will wait for another day - I'm tired of spending money and I know I'be got one more substantial order from Benchmark Works before it's all done.

Parts!

Right - Ava is completely broken down.  I picked out everything I need to media blast and then get powder coated:

Maybe next weekend I'll get a chance to blast - I just need to find enough time to get it all done at once and then drop it off for powder coat.  Tech tip: Barrington Motor Work's /2 restoration book has section on what parts should be matte black and which gloss - one of the best x- mas presents ever.

I dropped off my 74 r90/6 engine and tranny withTom Cutter at Rubber Chicken Racing in Yardly Pa. In that I know nothing about the engine that came with this project and that the '74 had inherent problems, I wanted someone who knew their business to go through it.  I may have bitten off a bit too much but we'll see.  Tom has promised me basically a brand new engine - better than stock.  I just know it won't be cheap.  But, the money I get from the Rabbit should cover it, plus, he's been cool enough to let me come over and do some of the grunt cleaning and polishing work to save some cash.

In the dog house is Tom Epperson frrom Epco mufflers.  I ordered conversion headers two and a half years ago and have seen nothing.  I didn't actually pay for them until September 2013 (at which time I added a set of mufflers too)  - to the tune of $1,000.  Through last November, I've talked to Tom at least a dozen times and it was always: "oh, I'm looking at them, they'll be sent out in a couple days" - I hate that kind of bullshit.  However, now that I've paid, I can't even raise him on the phone.  Tomorrow, I'll be talking to the credit card company to see if I can reverse the charges.  I really don't want to lose the $1,000.