1940 SS Knucklehead: People's Champ 5 Build" - Page 13 - The Jockey Journal Board

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Old 03-30-2017, 04:34 PM   #241
Ratso
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Default Re: 1940 SS Knucklehead: People's Champ 5 Build"

How'd you do that?
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Old 03-30-2017, 05:26 PM   #242
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Default Re: 1940 SS Knucklehead: People's Champ 5 Build"

I'm betting the first one was done with a ball end end mill on a rotary table in a mill, or a CNC mill. I bet Newman did his by hand with his air file!
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Old 03-30-2017, 10:55 PM   #243
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Default Re: 1940 SS Knucklehead: People's Champ 5 Build"

Quote:
Originally Posted by Ratso View Post
How'd you do that?
Quote:
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I'm betting the first one was done with a ball end end mill on a rotary table in a mill
Haha, nailed it, although the dynafile did factor strongly into the final shaping!
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Old 03-30-2017, 11:58 PM   #244
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Default Re: 1940 SS Knucklehead: People's Champ 5 Build"

The second one, though. Is that hand work?
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Old 03-31-2017, 07:53 AM   #245
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Default Re: 1940 SS Knucklehead: People's Champ 5 Build"

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The second one, though. Is that hand work?
File and lathe!
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Old 03-31-2017, 05:54 PM   #246
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Default Re: 1940 SS Knucklehead: People's Champ 5 Build"

Thankew.
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Old 04-03-2017, 11:10 AM   #247
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Default Re: 1940 SS Knucklehead: People's Champ 5 Build"

Made a shift knob from a marble and some 12GA 316.





Better view here:

https://www.instagram.com/p/BSU70KQl...en-by=ctnewman

Also made these vband exhaust spigots. I'm hoping I can weld or braze them onto the head, but I need to do some more research about that.

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Old 04-03-2017, 10:54 PM   #248
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Default Re: 1940 SS Knucklehead: People's Champ 5 Build"

beautifull work Newman....you are a true craftsman...
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Old 04-07-2017, 06:12 PM   #249
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Default Re: 1940 SS Knucklehead: People's Champ 5 Build"

great job with that black & white "shooter".
keep it coming brother!

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Old 04-14-2017, 08:52 AM   #250
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Default Re: 1940 SS Knucklehead: People's Champ 5 Build"

Scrambling trying to get the engine together and working on 3 things at once. Seat at at upholsterer, tins are at painters. Focusing on trying to get the engine built so that I can get the exhaust and foot controls built.

Here are some things that happened in the past week:

Made some special stud covers to close off the holes in the CE reg I modded.



Started working on some floorboard pedal thingers:





Always a shame grinding off (semi) pretty welds





I got this cast exhaust piece that I designed. It goes underneath the trans and will have vbands on both ends.



I welded my vband flanges that I made a few posts back to the head. Super high stress job. Took about 7 hours. Preheat, weld 3/8", back in the oven, repeat, then slow cool down cycle. Welds looked good and no cracks. Then I powdercoated them wrinkle black which may not be everyone's thing, but I like it. Valve guides and rocker shafts are one-off... I have a plan coming together there. Rocker shafts are out getting carburized now.



Last night I bead blasted and prepped the case for glyptal. Me and my buddy Dave at BA enterprises put new Jim's main races in the case and honed them. Cover bearings reamed, lots of threads fixed, etc. Hoping to put the bottom end together this weekend. I think I have all the parts.





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Old 04-14-2017, 09:30 AM   #251
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Default Re: 1940 SS Knucklehead: People's Champ 5 Build"

First I want that shifter knob, but you continue to impress...
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Old 04-14-2017, 09:35 AM   #252
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Default Re: 1940 SS Knucklehead: People's Champ 5 Build"

I personally love wrinkle black, my horseshoe is done in it, looks so good finished.

Flanges may be a god send, the old style ones are such a pain in the ass, my back pipe will literally not stay tight!

Lovely welding too man!
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Old 04-14-2017, 01:29 PM   #253
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Default Re: 1940 SS Knucklehead: People's Champ 5 Build"

Why is that little section on the left case near the breather channel masked off from the glyptal?

Thanks for continuing to post up progress!
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Old 04-14-2017, 01:51 PM   #254
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Default Re: 1940 SS Knucklehead: People's Champ 5 Build"

It's the scraper plate. Old timer who is helping me with my motor says it needs to be masked off, so i masked it off. He explained why but I was doing it at like 2 am and can't recall.
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Old 04-14-2017, 02:49 PM   #255
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Default Re: 1940 SS Knucklehead: People's Champ 5 Build"

Quote:
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First I want that shifter knob, but you continue to impress...
I thought it would look great on your bike as soon as I saw it!
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Old 04-28-2017, 09:56 AM   #256
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Default Re: 1940 SS Knucklehead: People's Champ 5 Build"

Been working hard.

Got everything from the cylinders down together permanently. Motor is rebuilt from the flywheels up. Doing all the motor work at BA Enterprises in Lockport NY. He's very knowledgeable. Waiting on valves before I can do final top end assembly.

Here's how it sits now.



But Dave was going out of town for Oley for the week so I brought the motor back home to start on exhaust and foot controls.

Fits in the frame well. Had some concern about the vband clamp clearance but I think I am golden.



I'm running an MM74E and if you have ever used one you know there is a little round spacer that goes under the mag bolting flange. It's purpose is to be able to drop the body to install the mag head. Well that idea is great but the spacer leaves a lot to be desired. I replaced it with this:



Next, I committed chopper blasphemy and machined some adapters to reduce my top end oil feed ports from 1/2-20 to M10x1.25. I did this because there are a lot of awesome banjo bolts available in that size, and I don't have time to be making bolts right now. Time is running out.



Last night I finished up my footpeg/floorboard/pedal things. You may remember these from a few posts back:








Hope to get them mounted and have some functioning linkage in the next week or so, then on to the exhaust.
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Old 04-28-2017, 11:36 AM   #257
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Default Re: 1940 SS Knucklehead: People's Champ 5 Build"

On the floorboards... trying to reverse engineer them between the "in progress" shots and the finished product.

Are the wavy fins in the final product inserted from the bottom of the slots shown before? Are they welded from the bottom with a slip fit so there's no gap or fillet to smooth or polish on top?

So rad BTW. I love mini-floorboards.

Are they going to be high-mounted? I imagine that with the whole skinny theme putting them at least on top of the primary (rather than beside) would follow logically...
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Old 04-28-2017, 01:57 PM   #258
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Default Re: 1940 SS Knucklehead: People's Champ 5 Build"

They are inserted from the top. There are small tabs that poke slightly through the bottom which I welded after polishing and installing.

My plan is high mids. I have to figure that out exactl placement still.
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Old 04-28-2017, 05:49 PM   #259
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Default Re: 1940 SS Knucklehead: People's Champ 5 Build"

you'll sell a lot of those floorboards at a buck apiece
very nice work
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Old 05-08-2017, 10:40 AM   #260
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Default Re: 1940 SS Knucklehead: People's Champ 5 Build"

Ok, got some work done the past couple days.

First things first I had to mount the footpegs, so I started by cutting out some 316 on the saw, then smoothing it and bending it up.







Then I welded on some gussets:



Then did a test fit. Seems to be going well so far…





Then I polished them up. This video shows what they looked like after polish. https://www.instagram.com/p/BTh-Uhjl...en-by=ctnewman

After that, I mounted the floorboards on.







It’s shocking how skinny it is!

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