'62 Chop, 4th Rebuild in 42 years..... - Page 10 - The Jockey Journal Board

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Old 07-17-2016, 01:28 PM   #181
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Put the tranny plate on the tranny and bolted it up, it all went fine until I tried to put that right side 5th bolt in, no go!
The slot in that right side frame bracket was just slightly too close to the left, so I had to file it on the right side,
and test fit about 3 times, finally it would bolt up....

Once I got it to fit, I decided to switch it to a stud for that slot, with a heavy duty washer and a nylock nut,
it all looks good to me now...

Went ahead and put the kicker and clutch release arm on the tranny...

Pulled the rear wheel back off so I could mount the oil can, it's looking good....


Of course I put some polish on it before hanging it on the bike...




Dug the generator out of the parts box, it was pretty grubby...


It took quite a bit of scrubbing and polish, but it cleaned up nicely...

It's the original 6 volt model 58R that came with this bike...

I've been told that these can be rebuilt with 12 volt parts, anybody know anything about that ??

More later,
Willy
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Old 07-17-2016, 01:49 PM   #182
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Nice
Stay with 6v is all good


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Old 07-17-2016, 03:54 PM   #183
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Getting closer!!!!
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Old 07-18-2016, 04:46 PM   #184
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Cleaned up the voltage regulator, it's an early solid state unit that also worked as a battery eliminator...


Put it back in it's usual location under the oil tank...


Painted and bolted up the sissy bar...

Just smoothed it out a bit, the old "Road Scars" are still visible
under the fresh paint....


Put the plate for the license and the safety tags on...


The safety tags are a joke here in Hawaii, just a way for the State to collect another $20/yr in taxes...

These are the last safety tags I ran, expired in April, 1990...

More later...
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Old 07-18-2016, 11:57 PM   #185
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

I'll bring that tire up next lunch date....You should get a new tube too.

I almost rode my bike today....
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Old 07-19-2016, 12:43 PM   #186
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Got everything I needed bolted back in place on the rear fender, so put the rear wheel back on...


Painted the headlight bracket and hung the headlight on the front...


One more shot...


Still need to clean up and paint the foot pegs, install the clutch assembly and the drive belt and rear chain, install and time the magneto, figure out the front brake master cylinder and hydraulic line, and do the oil lines, the fuel line, and the wiring.

But taking four of my grandkids out for the day gets top priority !!!
Aloha,
Willy
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Old 07-20-2016, 04:29 AM   #187
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

imagine having a granddad that cool,
building all that neat stuff in his shed!
your grandchildren must be really happy, i know i'd be!

nice to see this come together. very cool bike and story!
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Old 07-20-2016, 10:17 PM   #188
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

His grand kids probably think he's nuts....So does his wife. He is nuts, like the rest of us.
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Old 07-20-2016, 10:27 PM   #189
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Willie, I'm glad you're finally getting this done, maybe Brant will finally get the original back together too, that would be cool to see them together!
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Old 07-20-2016, 10:27 PM   #190
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

(^^^) hint hint
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Old 07-20-2016, 10:47 PM   #191
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Quote:
Originally Posted by KCgran View Post
(^^^) hint hint

IF I had another pan motor, that would be priority....I've even toyed with pulling the one in the other bike.
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Old 07-21-2016, 06:59 PM   #192
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Got a little time today, so started the cleanup on the shifter brackets and the rear brake MC brackets, and the MC itself...
Pulled the MC out of it's plastic bag, it looks bad...




It cleaned up pretty well in the solvent tank...




The insides were this venemous black goo, washed it all out, and tried to disassemble the piston, but
it wouldn't come out, will need a "bigger hammer"....

More Later,
Willy
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Old 07-21-2016, 11:12 PM   #193
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

I got another one if you need it....
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ROLLING DEATH

"In short, if you have engineering experience and are cautious and sensible they're fun and look great, if you're lazy and stupid, throw them on the bike and go for a ride you'll be dead the same day." -=JL=
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Old 07-24-2016, 01:44 PM   #194
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

My smallest hone is just slightly too big. The local Napa didn't have anything smaller. Tapped the piston further in as far as it would go, about 3/8". Then I used some good steel wool and my lil' finger and got it cleaned up pretty good, then with air it popped right out. Doesn't look too bad really, but as long as I have it apart I'll get new parts and rebuild it. The rubber cup looks like 11/16" diameter, haven't checked what the actual bore is supposed to be. Will do that. If I can get them, a new rubber cup and a new o-ring on the piston really is all I need. Plus putting a shine on the bore inside the MC....


Looked up the HD part #s,
41762-58A, mc repair kit
41766-58, washer, filler plug
And I can't find this part:
41770-58, plunger, mc

more later,
Willy

Later: Found the parts I need online,
and found the mc plunger in my shop....

Last edited by 2Loose; 07-24-2016 at 04:26 PM.
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Old 07-24-2016, 03:38 PM   #195
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Moving along nicely.
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Old 07-25-2016, 01:44 PM   #196
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

I wonder if I could get one of these to fit under that rear fender??



Avon AV72 Cobra 150/80-16 Rear Tire


It's rated as a tubeless bias ply, so I should not have a problem running
it with a tube on my spoked wheel...
Wish I could find a decent illustration of the cross section with dimensions to check
if it would really fit...
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Old 07-25-2016, 04:03 PM   #197
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Found the old wiring diagram....

It worked before, I'm sure it will work again...
Magneto ignition, so it keeps it simple...
Willy
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Old 07-25-2016, 04:14 PM   #198
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Quote:
Originally Posted by 2Loose View Post
Found the old wiring diagram....

It worked before, I'm sure it will work again...
Magneto ignition, so it keeps it simple...
Willy
Gold right there!!
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Old 07-25-2016, 04:46 PM   #199
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Quote:
Originally Posted by 2Loose View Post
Found the old wiring diagram....

It worked before, I'm sure it will work again...
Magneto ignition, so it keeps it simple...
Willy
Gold right there!!
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Old 07-28-2016, 12:35 PM   #200
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Ran into a problem....


My "police special" high output fan cooled generator does not fit into my Denver's frame, the scroll cage for the fan hits the left downtube....


I think this frame is sized for the smaller 6v generator that most of the street bike panheads were fitted with,
so now I am looking for one of those....



If I had caught this before painting the frame, I could possibly have done a modification to the frame to
accomodate this generator, but too late now....
Willy
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