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

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Old 06-19-2010, 01:47 PM   #1
2Loose
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Default '62 Chop, 4th Rebuild in 42 years.....

Did my first build on this '62 Pan in '68, it's had a couple rebuilds since, but has stayed essentially this way until now:

The frame is the original '62 frame, with my own homebrew hardtail welded on, didn't want to cut the neck, so left it stock, put on 18" over tubes on it, and dropped the back end down as low as I could and still be streetable, it handles fine and I've put many, many miles on this rig.

But I have had an old, original Denver's frame, in cherry unused condition, stashed away for a long time, can't remember, 20-30 years, stretched about 4" and with a 45 deg rake. I've been intending to move the hardware over from the present frame to the "new" frame for years now, and am finally getting to it.

Recently ran across an "old style" extended original HD springer, done right with the A-bone radius rods. Looks like about a 14" over setup. Put it on the frame and it just looks right, so I will be proceeding to transfer everything over and set it up with the "new" frame.

I'm also working on a '55 chevy, gasser style, and the bike is in the shop next to the gasser project, so I can put in time on both......


Already have had to do some small mods for the rear brake mount, clearances were needed, I'll take some pix and post 'em....


Here's the link to another thread here about this bike and it's "sister" '59 pan.
Aloha,
2Loose Willy

Last edited by 2Loose; 07-19-2010 at 04:20 PM.
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Old 06-19-2010, 06:48 PM   #2
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

That is some great history!
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Old 06-19-2010, 06:53 PM   #3
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

major improvement already, much better stance
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Old 06-19-2010, 07:01 PM   #4
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

2Loose,
That stance is awesome. I this is anything like your 55 Chevy or other projects, it'll turn out sweet. Keep us posted.
-Dan
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Old 06-19-2010, 07:12 PM   #5
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Ha, im also working on my hot rod project and bobber. Figure why im takeing so long...
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Old 06-19-2010, 08:54 PM   #6
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

watching this one
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Old 06-21-2010, 01:11 PM   #7
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Got the rear brake setup and the wheel mounted, needed some work, still some to do, here's a couple of pix:




Am workin' on the bike and the '55 gasser in my buddy's shop, Poncho Willie, he's got some cool projects going on too, we help each other out on these projects......

OK, set up a web page to keep track of this project:
LINK to 2Loose '62 Rebuild
Aloha,
2Loose Willy

Last edited by 2Loose; 06-22-2010 at 10:29 AM.
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Old 06-21-2010, 05:37 PM   #8
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

lookin good. to many projects and never enough room.
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Old 06-22-2010, 10:24 AM   #9
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Yeah, there's never enough time, plus I have 4 kids grown with their own families, that all takes time too, time I don't wanna miss out on! Sometimes I really want to just go "hide out" in the shop and work on the bike and car projects, and the wife says, "Let's go over to (fill in the blank)'s house for awhile....."

Whatcha gonna do? Sure don't want a domestic battle goin' on, so ya just miss out on some more time getting the (pick the ride! ) back on the road!

I had a great life up to now, am keepin' ahead of the bills, have stashed away over the years most of the parts I think I needed for my projects, and really enjoy the wrenchin' on my own projects, very cool!
Aloha,
Willy
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Old 06-22-2010, 10:44 AM   #10
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

It could also be a Denver's frame you got there...
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Old 06-22-2010, 11:05 AM   #11
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Bike looks awesome the way you "had" it and will look great with the new frame, I really think raked frames look slick.
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Old 06-22-2010, 11:45 AM   #12
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Lookin' like a good start to me. Be cool to see the progress, keep 'em coming!
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Old 06-22-2010, 02:14 PM   #13
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Quote:
Originally Posted by Danny F. View Post
It could also be a Denver's frame you got there...
Yeah, it could be, I was figuring either a Denver's or a Paughco, it's at least 20 years old, maybe as old as 30. Just don't remember anymore where I got it and how long ago, but it's been in the back of the storage shed for a long time!

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Old 06-22-2010, 02:24 PM   #14
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Looks cool man good luck with the build!
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Old 06-22-2010, 03:03 PM   #15
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Quote:
Originally Posted by 2Loose View Post
Yeah, it could be, I was figuring either a Denver's or a Paughco, it's at least 20 years old, maybe as old as 30. Just don't remember anymore where I got it and how long ago, but it's been in the back of the storage shed for a long time!

I'm pretty sure actually that it is a Denver's...
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Old 06-23-2010, 12:33 PM   #16
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Did chuck the rear brake spindle in a lathe yesterday and shortened it 0.2", and added 0.2" more thread, cleaned up all the parts and painted 'em, when it's back together will post pix. Did add a pic of the lathe work on the build website (link below).
Willy
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Old 06-23-2010, 05:15 PM   #17
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Bro I would love to see this thing some time if your cool with it I'll let you know when I make it to your island
mahalo
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Old 06-24-2010, 01:59 AM   #18
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

No prob man, that's very cool, do a pm here and I be there....
Willy
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Old 06-26-2010, 02:38 PM   #19
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

After the lathe work on the rear brake mounting spindle, everything fitted up perfectly.....

Now I have to drill, tap and relocate the hydraulic fitting on the wheel cylinder so it will clear the top frame tube on that side...
Always something !!!
Aloha,
Willy
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Old 06-28-2010, 01:53 PM   #20
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Found the right fittings I needed for that rear brake cylinder, got it drilled, plugged the original hole, now I have full axle/chain adjustment range back there!


Now I gotta work on getting that front end setup!
Aloha,
Willy

Last edited by 2Loose; 06-28-2010 at 01:54 PM. Reason: added pic
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Old 07-06-2010, 05:30 PM   #21
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

My wife sez I have too many projects! Probably that's 'cause she never sees me unless she comes out to the shop. I tried to put her to work on one of my projects, but she'd rather cook and poke around in the garden, that's fine by me!

I started pulling parts off of the "old" bike, decided to just do a few at a time and get them mounted properly on the "new" frame. Now that I have that rear wheel and brake setup the way I want, time for the rear fender and sissy bar. Like I said, I am keeping this one "old style", using the parts I started with 40+ years ago and just "upgrading" the frame.

I also pulled my old "narrowed" 18 over wide glide and 21 incher off the front of the old bike and put them on the new frame. An interesting fact I just noticed is that my old glide and the old springer are exactly the same length from the bottom of the frame neck to the axle! What are the chances of that happening? Guess it was meant to be! I can run either front end once I get the rest of it setup the way I want!

Here's my old bike after those parts were pulled off:


Here's what the new setup looks like with those parts on. The fender and sissy bar are just "propped" up on there, I need to make some brackets for this setup:


Link to more pix on "page two"
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Old 07-07-2010, 10:27 AM   #22
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

That frame and springer front end looks just like my first bike back in 1975. Very cool. Tattoo
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Old 07-07-2010, 12:39 PM   #23
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

My buddy, the guy I got the springer from, just got back from his travels, so I should be able to pickup the rest of the parts to mount that springer on this frame. The top pieces (triple clamp?) are missing, but he knows where they are....

I need to pull the oil tank off the old bike and use it as well when fitting the fender on the new frame, as the back end of the oil tank hangs on the fender....
Aloha,
Willy


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Old 07-07-2010, 12:56 PM   #24
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

I'm excited to see what the finished product looks like on the new frame!
Personally, I dig the extended fork tube look... don't change it!
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Old 07-07-2010, 01:57 PM   #25
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

I had originally set the front end up with the original '62 triple trees, just added the18 over tubes, and was running the old original drum front brake, which was nearly useless, a "hill holder" was about it!

Ran across these narrowed trees, which came with a narrowed axle to match, and really liked the result! I'm getting too old to run without a front brake though, so I think I can fit in a disk and caliper up there, measured it and there enough room, I'd have to do some custom fitting though to make it work. Keeping the old style star wheel hubs too.

I also wanted this frame to be slightly "up" in front, as I want to run the front exhaust pipe down under the frame rather than through it, a way better setup!

Gotta go setup the throttle linkage, clutch linkage and fuel system for my 55 chevy gasser project, so will be away from the bike for awhile....
(well, I might sneak over and work on it a little here and there....)

Aloha,
Willy
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Old 07-14-2010, 02:27 PM   #26
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Got some more work done on this.
Got all the brackets welded in for the rear fender and it's all mounted good and solid now. Put the trans and oil tank in place, that's all done, set the seat on and now need to fab up the mounts for the seat. A buddy back in the 60's with an old Indian Scout had the original steel seat pan, and we made a fiberglass mold off of it. I made this seat from that mold and ran it on my original bike for over twenty years (see top pix page two). It fits my butt perfectly, did over 6,000 miles on that seat the June/July of 1975 along the West Coast, across Canada, down the Great Lakes, visited the HD factory in Milwaukee, then had to hit Nashville, then back across the midwest to Calif. to ship the bike back home to Maui. That was a great trip! Went solo all the way, but kept running into really great folks everywhere, so we'd ride, camp, party awhile, then go our own ways. Probably the best trip I've ever been on!
Bike is looking like this now:

Link to new pix, Page Three
Aloha All,
Willy
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Old 07-19-2010, 04:15 PM   #27
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Got the seat mounts welded in place, got the correct spacers machined for the oil tank and it is bolted in place correctly, got a new steel Sporty tank and moved the filler to match my old bike tank (it is fiberglass and is in poor shape, needed to replace it....)
now I need to mount the tank. Getting close to moving the motor over.


Will be gone on a trip for awhile, family stuff, will move the motor over when I get back....
Aloha,
Willy
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Old 07-19-2010, 09:43 PM   #28
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

I like the indian verrtical seat on there, looks good.
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Old 07-19-2010, 11:04 PM   #29
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

cool I like it
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Old 07-20-2010, 12:26 AM   #30
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

That seat is totally adjustable, holes in the support for forward and back, and that link to the pivot is adjustable (bend it!) to put the front in the best position, too high and it hits the pelvis with numbing effects I don't like !!, too low and I slide forward too much when i brake hard...
When I did my long tour in '75 I adjusted that seat many times before I got it right, I see that happening again here....
Aloha,
Willy
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Old 07-20-2010, 07:43 AM   #31
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Very cool ! Funnny how I am building an old knuck on a denver frame, got a 55 gasser going together same time too !! MY wife also puts in garden, cooks, and I got three young boys ages 1-18 .....stay focused man !!!!!! I know it's tough sometimes !! LOL
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Old 07-20-2010, 05:22 PM   #32
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

I think there's more of us around than most people realize. I know of at least three guys just here on this little island involved in old bikes and gasser style cars, but trying to get them involved in the internet is like pulling teeth! They won't even let me put up pix of their projects on the 'net....

I came close to buying a local knuck couple of years ago, but it ended up going to Alaska for far more money than I was willing to pay. Too bad, I love the old knucks, but ended up with pans most of my life, also very cool bikes...

Have you posted any pix of your projects anywhere?
W.
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Old 07-22-2010, 08:00 PM   #33
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Talking Re: '62 Chop, 4th Rebuild in 42 years.....

got some pics over next door.....my handle is the same mr haney

going to the drag strip sat for rock and race ! historical dragway 42

wish my 55 was ready.............takin an evo out there to beat up on !
thats all they really good for
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Old 08-04-2010, 05:15 PM   #34
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Just got back from the mainland. Visiting family.
My rebuilt '62 FL lower legs were here (new bushings), and a pair of new 16" over tubes, so started setting up the front forks the way I wanted, which is to duplicate the same way I did it 40 years ago.
I used two sets of springs in each fork, and a lighter oil, to get them to ride nicely in the extended and raked configuration.
Link to story and pix on my front fork setup
Aloha,
Willy
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Old 08-07-2010, 01:54 PM   #35
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

A buddy of mine was telling me I should run this two-spring setup in my forks with a flat washer between the two springs in each fork. He says the two springs twist as they compress and expand, and that they can bind against each other. I can sort of see that, but I ran this setup for 20 years and they did not look bad at all when I took them out of the old tubes. There are shiny areas along the outside of all four springs where I can see that they were rubbing on the inside of the fork tubes, but i didn't see any evidence of wear between the two springs where they were touching each other. My buddy runs an old school chopper shop, and says that certain suppliers of extended forks always supply those washers to put between the springs. I can certainly do that, I don't see where it would hurt anything to do that, I just didn't see any evidence of that happening in my particular setup.

The new fork legs I got from Frank's, came with a spacer to run with the stock springs, with a washer to put on top of the springs, between the springs and the spacer. Guess I could put that washer in my setup between the springs.

Any comments from you guys on this?
Aloha,
Willy
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Old 08-08-2010, 01:57 AM   #36
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Hey Willy,
Glad you had a good trip. I got nothing for you on the washer issue, Ive never had to deal with that. It can't hurt though, better safe than sorry.
-Dan
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Old 08-09-2010, 02:22 AM   #37
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Only thing is, I've learned a long time ago that any old bike is a "flyin' formation of lock-tite" (of course this was only after lock tight came out, before that we tightened bolts at every stop!)

Try a '63 BSA twin carb Lightning, my second bike in this world, ran great, as long as I kept it tight and tuned!
In 1967 here on Maui, in the middle of this quiet little island, a couple of us guys (I was 25) used to do the run from Kahului over the cliff road (the Pali) to Lahaina and back, running hard and fast.
Glad I survived that....

These days (daze?), Harleys are better for us old Dudes, go slow, don't get in trouble any more, ride in comfort, but remember the past !!!
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Old 08-09-2010, 02:17 PM   #38
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

very cool
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Old 08-09-2010, 06:19 PM   #39
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

bitchin thread man.
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Old 08-12-2010, 11:03 AM   #40
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Travelin' with family right now, will get back to the bike in another week...
Need to weld in some steel plugs into the top tube, threaded, to mount the tank on.
Then put the motor in and setup the primary drive (an old Primo belt drive), the mousetrap and clutch setup, the kickstand, front footpegs/brakes/shifter, then pull it all apart and paint everything....

Looking for a front disk brake I can run on that harrowed wide glide setup I have with the star hub I have on that 21 incher. Might have to carve me a custom adapter on the lathe to mount a disk on there. Gettin' too old to run a bike without a front brake anymore....
Too many idiots out on the road with the windows rolled up and yakin' on their cell phones, a rolling death squad!

Much Aloha to all.....
Willy
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Old 11-07-2010, 11:40 AM   #41
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Lots of delays, family and home, they come first, always have, but back on it now, plus my '55 Chevy "nostalgia" gasser project needs to get finished so I can run it at our local track next year, so putting in lots of time on that one too....

Ran across another fuel tank I like, and wanted a little change from what I was running "back in the day", so set it up and I like the look....



Now to move the motor and remaining parts over from the old frame and get it to the point where the welding is done and I can take it apart for final paint and assembly....
Aloha,
Willy

Link to more pix on pg. 3 (scroll down a ways....)
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Old 11-08-2010, 10:04 PM   #42
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Great work
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Old 11-10-2010, 11:07 PM   #43
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

The only problem with this new tank is that the handlebars hit the tank at fairly shallow fork angles, set the stops so they did not hit the tank, but for parking and other maneuvering the fork angle is not very good, would take a lot of back and forth work to get the bike into a tight space, stuff like that, so I was looking at how to get more angle....

Dug up a set of 6" handle bar risers I had in the back of my shop, replaced the 4" risers I had on there, and a slightly wider set of handlebars, about 2" each side, and was able to dramatically increase the fork angle for maneuvering, took the fork stop bolts all the way out, it's at the max unless I grind some off the bottom triple tree where it hits the frame stop, but it looks pretty good now....

I like narrow bars, and I like drag style bars, these are a little wider than I like, but maybe because I'm now 68, it's good to have a little wider set of bars, easier to maneuver that front end around when parking, etc....


Couple more pix at the bottom of this page.... (Link)

Aloha,
Willy

Last edited by 2Loose; 11-27-2014 at 03:38 PM.
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Old 11-11-2010, 12:08 AM   #44
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

WOW!!! Great (re)build thread!!!

I like the narrow bars better too, but wide bars are more stable.

68??, and you're still riding a hardtail???

HOLY COW!!! you've got MY RESPECT!!!
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Old 11-11-2010, 02:47 AM   #45
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

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The only problem with this new tank is that the handlebars hit the tank at fairly shallow fork angles, set the stops so they did not hit the tank, but for parking and other maneuvering the fork angle is not very good, would take a lot of back and forth work to get the bike into a tight space, stuff like that, so I was looking at how to get more angle....

Dug up a set of 6" handle bar risers I had in the back of my shop, replaced the 4" risers I had on there, and a slightly wider set of handlebars, about 2" each side, and was able to dramatically increase the fork angle for maneuvering, took the fork stop bolts all the way out, it's at the max unless I grind some off the bottom triple tree where it hits the frame stop, but it looks pretty good now....

I like narrow bars, and I like drag style bars, these are a little wider than I like, but maybe because I'm now 68, it's good to have a little wider set of bars, easier to maneuver that front end around when parking, etc....


Couple more pix at the bottom of this page.... (Link)

Aloha,
Willy
Great stance you've got there. IMO there's another problem with the new tank: To be honest, it doesn't look as good as the old Frisco sporty tank.
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Old 11-11-2010, 01:21 PM   #46
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

You're right, the old Frisco style sporty tank was the "deal" back when, and with the fiberglas tank it was pretty easy to move that filler up where I did, with the "erection tube" on it! (Always got plenty of comments on that !!!) (As in "Hey, Willy, yer bike's got a hard on.....") When I tried to do that in steel, I kept getting pinhole leaks! Welded up 4 to 6 pinholes the first time, more kept popping up! After 4 or 5 sessions with the welder chasing my tail and those damn pinhole leaks, I put it aside for now, might come back to it later, but this tank was around at a buddy's, so tried it, a few more gallons, with the old setup I was always stopping to top off the tank, and carried extra gas on my mainland jaunts!

Might still go back to the sporty tank, if I can fix those pinholes! Don't like "Kreem" and the like (tank sealers), have had bad experience with that stuff eventually (over time) coming loose and fouling up the whole fuel system!

This will do for now, but yeah, I'd like to run the Sporty tank again some day....
Aloha,
Willy
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Old 11-11-2010, 01:29 PM   #47
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

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68??, and you're still riding a hardtail???

HOLY COW!!! you've got MY RESPECT!!!
Heh, heh.....
Thanks, those springs under the seat work really well, plus I plan to get back down to my old "fightin' weight" (about 160), another 20 lbs to lose and I'll be there.....

My two other bikes are swingarm frames (a '59 FLH, "local boy" fatbob style, but apart right now; and a '91 FXDB Sturgis Special Dynaglide....)

I'm starting to order parts for the '59, now that I have legal title to it, will post a build thread on it when I start that project....
(There's a thread here on Jockey Journal on how all that came to be...)
Link To "A Good Bike Story"

We'll see just how well I do on the old hardtail......
Aloha,
Willy

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Old 11-16-2010, 10:41 PM   #48
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

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You're right, the old Frisco style sporty tank was the "deal" back when, and with the fiberglas tank it was pretty easy to move that filler up where I did, with the "erection tube" on it! (Always got plenty of comments on that !!!) (As in "Hey, Willy, yer bike's got a hard on.....") When I tried to do that in steel, I kept getting pinhole leaks! Welded up 4 to 6 pinholes the first time, more kept popping up! After 4 or 5 sessions with the welder chasing my tail and those damn pinhole leaks, I put it aside for now, might come back to it later, but this tank was around at a buddy's, so tried it, a few more gallons, with the old setup I was always stopping to top off the tank, and carried extra gas on my mainland jaunts!

Might still go back to the sporty tank, if I can fix those pinholes! Don't like "Kreem" and the like (tank sealers), have had bad experience with that stuff eventually (over time) coming loose and fouling up the whole fuel system!

This will do for now, but yeah, I'd like to run the Sporty tank again some day....
Aloha,
Willy
Sounds to me like you MIG welded your steel tank. And unless you're good enough with the mig to run a continuous weld seam on light gauge material without burning holes, mig welding a fuel tank will be the exercise in endless chasing of "pin holes" and chemical patch-ups you describe.
Don't feel bad; damned few people are skilled enough with a mig to assemble or modify a leak-proof tank.

A small (2.5 gallon) Mustang tank would look great on there if you're not up for fabbing a custom tank.
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Old 11-17-2010, 12:31 AM   #49
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Great looking build, I really dig the tank, it goes nice with the bike... Can't wait to see it finished, I don't see too many bikes like this around the islands...
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Old 11-22-2010, 11:36 AM   #50
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

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Sounds to me like you MIG welded your steel tank. And unless you're good enough with the mig to run a continuous weld seam on light gauge material without burning holes, mig welding a fuel tank will be the exercise in endless chasing of "pin holes" ......
Yeah, migged it with my small Lincoln with .023 wire, tacked the "patch" in place over the hole where the original fuel cap was in about 12 spots, and then welded up between the tacks, a little at a time to keep the heat/warp down, then ground it down smooth, it came out looking great, but had about 5 pinholes when I tested it, welded those holes, and 5 more popped up, different places, kept happening, finally gave up for now......

I'll run this other tank, not that hard to change tanks later if I want....

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Old 12-03-2010, 12:48 PM   #51
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Got some more parts cleaned up and on the bike, put it on the ground to check out the kickstand and a few other things, rode it around a bit with a buddy pushing, felt good !!!!

After some pressure washing, pulled the original '62 motor out of the old frame, even after a lot of pressure washing, it is still "not pretty", gonna need more clean up before I'm happy with it. It's on the bench for now, will pull the top end off and check it out inside....
Am thinking (hoping) it only needs the minimum, hone the cylinders and new rings, and a valve job....

BTW, Those are old AEE finned Pan covers there....
Aloha,
Willy

Link to new page 5

Last edited by 2Loose; 11-27-2014 at 03:41 PM.
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Old 01-10-2011, 05:48 PM   #52
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Found a set of old "buckhorn" bars in a "discard" pile at a buddy's shop, tried 'em out, had to straighten 'em out a bit, and shorten the ends a bit to suit myself, think they look pretty good. Easy enough to switch back and forth between these and the flat drag bars....
Aloha,
Willy




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Old 01-10-2011, 06:30 PM   #53
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Those bars look better with that tank. Looking good over all. You are still going to put the springer back on right?
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Old 01-11-2011, 01:20 AM   #54
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

I like the chopped buckhorns and tall risers.
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Old 01-11-2011, 10:09 AM   #55
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

The chopped down bars look cool...did you chop down the grips as well or is a trick of the picture?
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Old 01-11-2011, 10:23 AM   #56
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

whats the story on the old frame? are you going to sell it?
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Old 01-11-2011, 10:23 AM   #57
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

i love that buckhorn bars..
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Old 01-11-2011, 12:14 PM   #58
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Those grips were already shortened when I ran them on the drag bars back 20+ years ago, just pulled em off and put them on the buckhorns after whacking off about 4" of bar on each side. The bucks were twisted about 10 deg. and pushed in about an inch and a half on the right side, I was able to take that out of them and get them squared away close enough you can't see it without a template. Used a couple of cardboard templates from the left side to match the right side against when straightening them.

Those risers are the 6 inchers I had been running with the drag bars before. Also had a set of 4" risers I had been running with buckhorns when I originally setup the bike in '69. Those bars got bent in a minor collision about '75 or so, put the drag bars on then and had to switch to the 6" risers to clear the tank. I put the 4" risers on yesterday just to see how they would look, can't decide which I like better, will take a pix for you guys to see later today.....

If I push the throttle grip on all the way on the right side, it comes up against the start of the handlebar curve enough to cause the throttle internal portion to bind against the outer shell after tightening down the screws, looking at how to cure that, backing it off down the handlebar a quarter inch or so cures that, but then it offends me as I sit on the seat, doesn't look right, I could back the right side grip off a similar amount, but sometimes I get hardnosed about such things, and determined to "fix it the right way"...... (whatever that is....)

Anyway, this project (like my 55 chebby gasser project) is an effort to use as much old parts, stuff laying around my shop or my buddies shops, as I can, without buying anything, or fabbing from scratch or other parts as much as I can, sort of a challenge there!

That old springer is still available, but has some cracks where the old A-bone radius rods are connected to the upper portion of the old springer. We (my buddies and I) think that was done with braze, than chromed, as that was the technique used way back then...
.
If my memory is correct, the old springers were put together by Harley Davidson with braze, oven brazed, and when extending them, the common practice was to fit the upper stubs of the chopped springer closely into the wide ends of the model A radius rods and braze then in place. If I am correct, likewise the lower ends of the springer was inserted into the lower end of the radius rods and brazed in place, but we do not know for sure if this one was done that way. I think the faint hairline cracks I am seeing at the upper joints on both legs are probably just the hard chrome cracking from normal flex in those legs, but it still scares me a bit. My solution is to find out how far those upper stubs insert into the extensions, drill two holes crosswise, one above the other, through the extensions and the stubs, and plug weld them on both sides of each leg. I think that would make them considerably stronger, but still, those hairline cracks at the upper junction between the original springer legs and the radius rods bothers me! Would hate to find out I was wrong at 70 in heavy traffic or on a curvey road......

The old frame is a part of the family, gonna hang it in the shop until I'm "make" (Hawaiian for dead, pronounced maa -kee, when a Hawaiian's bike is so trashed it will probably never run again, it is said to be "Make-Die-Dead!!!")!

Pulled the heads off the old motor, looks good inside, need to mike it, see how worn it is, if it looks good, will grind the valves, and button it back up and run it as is! Those barrels were "aluminized" way back 40 years ago, and are pretty burnt on dirty now. Cleaned up the heads with "oven-off" and some wire brushes, looks pretty good, want to clean the barrels the same way, but gotta keep that chemical crap out of the insides, maybe after I bolt the heads back on I can give those barrel fins a try with the chems, pressure washing wouldn't take it off, although it cleaned 'em up remarkably well!

Anybody here use or have used a Joe Hunt mag? Do they need anything other than a good points cleaning before restarting them after a long layoff? Like do the magnets need to be recharged or anything like that? Never had any problems with this mag back when I was running it daily, other than the occasional points cleaning and resetting the timing. Ran with no battery all those years, and when turning on the lights at nite, never knew for sure if they were gonna come on or not, ran an early "black box" battery eliminator, straight off the old 6 volt police spec fan cooled generator, and want to keep it that way.

Gonna run the narrowed wide glide for now, it's all rebuilt, new lower leg bushings installed and reamed to fit the new tubes (replaced the old 16" over tubes from "forking by Franks", with new ones from the same guys !!!!!). but where I didn't run a front brake before, I want to put one on now. I have an old beatup pretty useless condition front drum brake, looking at taking the hub portion of that brake and turning it down on a lathe to be able to fit a disk on it, and I have a couple calipers off of an old Kawasaki I can use, make my own disk setup to fit that narrowed front end with the original star hub! We shall see.

Yes, I do still want to run that springer, but I gotta be sure it is safe to run before I do!
Aloha all,
Willy

Last edited by 2Loose; 01-11-2011 at 12:30 PM.
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Old 01-11-2011, 01:36 PM   #59
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

those buckhorns totally complete that front end, im liking this build alot!
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Old 06-07-2011, 01:32 AM   #60
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Decided to do a total rebuild of the motor. Health ain't been so good so it's goin' slower then I want, but is slowly moving ahead. Heads all done, valve job, new valves and guides, now just gotta get that bottom end done!

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Old 07-04-2011, 02:18 PM   #61
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Haven't forgot this project, some severe health issues have kept me away from it, but it WILL get done!!!!
Aloha,
2Loose Willy
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Old 06-15-2012, 01:15 PM   #62
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Put an update on my other thread.....
LINK to motor rebuild thread........
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Old 06-15-2012, 01:26 PM   #63
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Looking Good on the Bikes....

Sure would like to see what the 55 Chevy 4X4 looks like...



Got a love going on for Old Trucks
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Old 06-16-2012, 01:13 PM   #64
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

If that's yer truck above, it's look'n pretty damn good too......

All of my biker friends also love old trucks, must be something in the blood....
I've got two, a '58 chevy I prostreeted 12 years ago, and the 55 I 4wh converted 10 years ago, I enjoy 'em both a helluva lot!!!

I've posted some pages on my 55 4x4 truck project over the years, just updated it with the work I'm doing now (LINK to my web site.....)

Ford 9" in back, the rear fenders were toast, got some wider 'glass fenders, widened the box a bit, and made that angled step to match the wider fenders to the cab. Have the front axle apart right now, it came out of an early 3/4 ton chevy truck as I recall, am switching to a cross steer setup, requiring quite a bit of work to do that, and doing some work on the Olds 455 that I originally pulled out of a 70 Toronado 10 years ago....

Enjoy my site, it's a fun truck and needed some "upgrades", I've had it 10 years now....
Willy

with 55 Chevy Viking front fenders and grill....

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Old 09-05-2012, 06:36 PM   #65
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Still dealing with some health issues, and have made several trips, family stuff, back and forth to Oregon and Washington. Plus working on the 55 truck (above) and my 55 chevy "gasser"....

But made some progress on the panhead, almost got it back together, some posts here on that project (LINK)....
Willy
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Old 11-06-2013, 12:02 AM   #66
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

I keep getting sidetracked by my hot rod projects, but keep coming back to my beloved panheads when I can....

Running these early AEE narrowed triple trees, with a star hub and a 21,
16" over on this early Denver's frame, custom built for me to my specs....
Am getting too old to try to run without a front brake like I used to do,
So am looking at trying to adapt a nice looking disk onto this front setup,
But have not found anything I like yet.
I can machine an adapter flange that will bolt to the star hub, with a disk
that will fit in here on the left side, just need to find the right brake unit to fit in here...
It's my nearly 50 year old 2 wheel "hot rod", and I intend to put it back on the road....
Last ran in '91....
Any ideas out there on my front brake question?
Aloha,
Willy
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Old 11-06-2013, 06:02 AM   #67
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

A front brake is a good thing. Are you needing a thin caliper? Got any measurements in mind?
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Old 11-06-2013, 08:15 PM   #68
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Woa keep it coming man it's gonna be a great chop when she done!
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Old 11-07-2013, 06:06 AM   #69
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

It needs the girder!
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Old 11-07-2013, 11:15 AM   #70
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

I originally set up the bike (in 69) with the stock triple trees and the stock front brake with a 21, and the 16 over fork tubes. That brake was worthless for stopping anything, was barely a "hill holder", so I canned it and put the narrowed trees on, with a narrowed axle and no front brake. Ran it that way for many, many years, including one 6,000 mile mainland trip in '75, including the Black Hills Rally, with no front brake.

I'm gettin too old for that though, want a good front brake these days, too many crazy drivers out on the road these days turnin left right in front of ya....

Found a nice oil tank for this ride from another JJ member...
Willy


No I didn't delete this photo, don't know what's up with Photobucket!

Checked it out, it's gone, no notice, guess where my relationship with Photobucket is going???

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Old 02-19-2014, 01:24 PM   #71
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Ran across this old pic recently, taken in about '70 I think, my oldest son going for his first ride around the block with me, he wasn't too happy, but was willing to give it a try!! The bike still needed paint and a p-pad on the rear fender....


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Old 02-20-2014, 02:43 AM   #72
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

My buddy has one of these disc adaptors on his 73 shovel. I think the drum bolt pattern on the mid star hub is probably the same bolt pattern as star hub drums. If so, this would work for you.
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Old 02-20-2014, 12:14 PM   #73
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

i don't think that type of adapter will work with narrow trees. you might have to use a sportster drum front hub or maybe you can squeeze a single piston caliper in there as they are really narrow on the inside.. how much room do you have for a disc?
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Old 02-20-2014, 04:03 PM   #74
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

I'm looking at using a similar front hub setup on my Knucklehead, with the star hub disc adaptor. The setup is slightly too wide to fit between narrowed trees. Planning to narrow the star hub to fit it all in.



The distance between my trees is 6 inches. The hub assembly with adaptor measures 6 inches across, but needs to be a bit slimmer for the hub to be centred. I figure if I take about 1/2" out of the hub & a small amount off the adaptor it should all fit.

Performance Machine have just released a vintage looking 4 piston front caliper that looks pretty good.

http://www.performancemachine.com/mo...n-caliper.aspx


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Old 02-23-2014, 11:49 PM   #75
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Cool info, many thanks....
the motor is slowly coming together. Was missing a few parts, had to wait for $$ then the order to arrive. Sometimes it's a slow boat to china I think....
Willy
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Old 03-10-2014, 02:57 AM   #76
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

The motor is done, just like I did 'er 40+ years ago, she's still a pretty lady!!!

tomorrow I'll fit 'er in the Denver's frame....

The narrow trees I've got hangin on there have a lot of side to side flex in them that I don't remember from when I shut 'er down for motor/tranny problems. But I found the wide glide trees, might put them back on and see if that flex is still in there, and have more room for the new brakes...
Aloha,
Willy
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Old 03-10-2014, 07:46 AM   #77
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Now^^^^^ That's a beauty!!!!^^^^^^^
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Old 03-10-2014, 10:48 AM   #78
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Hey Zeeman, did you successfully narrow that star hub and the brake adapter?
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Old 03-10-2014, 02:35 PM   #79
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

mmmmmmm
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Old 03-10-2014, 02:43 PM   #80
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Looking good man !!!
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Old 03-10-2014, 03:30 PM   #81
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Yeah this is coming together very well.
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Old 03-11-2014, 06:08 PM   #82
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Loaded in the '55 fourby and headed to the other shop:

But had to stop by the local tavern on the way for beer and a burger!
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Old 03-11-2014, 10:30 PM   #83
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

after a coupla beers to lubricate it, the motor slid right in....


Want to work on getting a better fit on that rear fender to the tire.
Pickin' thru various shades of red tryin' to match the original color. Got no record of what that was, only remember it was many, many coats of lacquer, with lots of rubbing, that was the hot setup "back in the day"....
Aloha,
Willy

Last edited by 2Loose; 03-11-2014 at 10:39 PM. Reason: brainfart
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Old 03-12-2014, 12:23 AM   #84
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Shit yes!!!

Now to wire and fire. WE need to take the tank or something to a paint shop that has that special tool....
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Old 05-30-2014, 01:29 PM   #85
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Seems like there's been a bunch of delays keeping me away from this project....

Whether it's got 4 wheels or 2 legs, it's been one problem after another to deal with....

But finally got back on it this week, dug out the old Primo belt drive parts and checked it all out, need to find a belt for it, but most of the parts look good to go....



This is the primary drive I used for a good many years on this bike in the 70's and 80's...





The plates all move smoothly on the studs and on the inner lugs on the drum, it was all working smoothly when I took it apart....

Will polish this up a bit, then I need to find the belt, or buy a new one, and get it on the bike.

The kick stand is kinda loose under the frame when folded up, need to figure out a way to hold it about here when it is folded up, as long as it clears the belt drive....



More pix here (Link)....
Aloha,
Willy

Last edited by 2Loose; 05-30-2014 at 02:45 PM. Reason: Ahhh, I just missed you guys....
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Old 05-31-2014, 12:00 PM   #86
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

I would ask when are you going to be done..... Then I would hve to answer the same question.

I forgot that had a chrome drum. I need to look for an old patina'd chrome clutch hat or something to keep the "driver" in character.
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Old 11-24-2014, 05:29 PM   #87
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Sheesh,
how did it get to be Thanksgiving week?
Well, way too many trips to the mainland and other islands (family stuff),
a surgery, and kept catching colds that slowed me down, plus problems with
my '58 truck and my '55 gasser, have kept me from making any progress on this bike.

It still sits pretty much this way:


so will now be tearing it down and cherry out the frame, tank and fender and paint. Then back together again, will post some pix as the painting starts....
Going to have to travel again in 3 weeks, so let's see how far I can get with this....
Aloha,
Willy
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Old 11-27-2014, 07:12 PM   #88
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

As I mentioned in one of the posts above, before I tear it back down for paint, etc, I wanted to get a good fit on the kickstand. Put the clutch assembly and drive belt on and checked that out....



It hangs down quite a bit....

Put some blocks under it to get it up as much as I can and still clear the belt....



Considered welding on a piece of 1/4" rod bent in a shape to catch the end of the kickstand and hold it in this position. Then decided to just bend it up a bit and see how that works, heated it near where the spring is connected to the kickstand....



I got it up as far as I can without rubbing against the drive belt. It's pretty close, but it's not touching. It was hitting on the frame at the end, a piece of rubber hose fixed that....



It looks good to me....



I can always make further adjustments later....
Now for tear down and paint....
Aloha,
Willy
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Old 11-29-2014, 10:03 PM   #89
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

I've run this bike for many years with no front brake, but think it is time to put one on.

Had an '84 Suzuki front fork assembly on the junk pile, pulled it out for a look....


Also had the calipers, a pair of grease balls....


Cleaned up the left side caliper, looks good to go....


Loaded the cleaned up parts in, now to find a rebuild kit for this caliper....


Will polish up the caliper a bit more, I think it will look good on that front wheel.
Now to design a rotor carrier that will fit in and bolt to the star hub....



One inch is not a lot of room, but I think it is doable....
Aloha,
Willy

More Pix at the home server
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Old 11-30-2014, 11:09 AM   #90
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

One question,
I'm looking at mounting the caliper either at the top of the rotor, where it would pull on the anchor link from the fork slider, or at the back of the rotor, at the 3 o'clock position, where it would be pushing up on the anchor link to the fork slider. I like the looks of the 3 o'clock position, but wonder about the effects of the caliper pushing up on that anchor link ??

Any ideas?
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Old 11-30-2014, 12:56 PM   #91
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

as long as the caliper bracket is bolted in good there should be no problem at 3:00. look at fab kevins design
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Old 11-30-2014, 04:44 PM   #92
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Willy,
Sometimes those dog-gone kick stand springs stretch out to the point where they just won't keep the arm retracted snugly. The length on a stock spring (even on an extended length kick stand like yours) that's just laying on the bench with no strain on it, is 2-7/8" from end to end including the hooks. Sometimes that's the "cheap fix" .

Geo.
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Old 12-01-2014, 01:41 PM   #93
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Think I got lucky, George, on this one, the spring is pretty good, had a difficult time stretching it far enough to get it on the kickstand, and it pulls it up snug against the frame rail, where I know it would be rattling, so the piece of rubber hose I think will cure the rattle. The shape was just hanging too low for me, and it was not bad before when parked....



So that bend I put in it will give just a little more lean over when parked, it might even need a little more, which I can give it by just shortening the kickstand, if it needs it.

Later I might put a rubber pad on the frame where the kickstand touches it, to eliminate that piece of hose out there on the end of the kickstand....
Willy

Last edited by 2Loose; 12-01-2014 at 01:53 PM.
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Old 12-01-2014, 02:33 PM   #94
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Here's two shots showing how much I changed it. Not much, but with new, clean rubber on the bike, I know I will get "into it" on occasion, and I wanted that kickstand tucked up out of the way, don't like things draggin' on the ground when crankin' thru the corners....

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Old 12-01-2014, 03:35 PM   #95
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Back to the front brake, took that Suzuki wheel apart, cleaned up the left side rotor and rotor carrier, and had to just try it on the wheel. The rotor carrier is too wide, but with it and the original front brake drum to get the bolt pattern for the star hub, I can come up with a design to fit this wheel....

Breaking down the wheel....


Everything was lock tighted together, needed a "cheater" to break 'em loose...





Parts look good....




Had to try it on the wheel, but that carrier is too wide....




More later,
Aloha,
Willy

Last edited by 2Loose; 12-01-2014 at 07:08 PM.
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Old 12-02-2014, 11:14 PM   #96
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

OK, got to put these parts together....


Just stacked 'em up for a look....


one way to go....


Or mod the Suzuki carrier....

Choices, choices...

More Later,
Aloha,
Willy

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Old 12-03-2014, 07:37 PM   #97
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

That caliper is nice looking and so are the stacked up parts. I can dig it cause my chopper has a 77 jap rear brake
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Old 12-03-2014, 08:03 PM   #98
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Visited my machine shop buddy, thought about modifying that Suzuki disk carrier vs making a new carrier from scratch, decided on the "new" one. See sketch above.

We'll machine the OD of the part that goes in the star hub with the 5 original HD bolts, I'll tig it to the plate, then he will machine the whole thing to the final specs to keep everything straight, no wobbles....

So I'm hunting for raw materials now.
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Old 12-04-2014, 11:31 PM   #99
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Found some 3/8" and some 3/4" steel plate today, will mark it up for my plasma cutter and take some pix....
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Old 12-07-2014, 02:10 PM   #100
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Found some 3/4" and 3/8" mild steel plate:


Cleaned 'em up a bit and marked 'em for the cut:


Cut 'em out slightly oversized, welded 'em together, will finish 'em up on a lathe:


Aiming for this:


It'll be interesting to see how many questions I get about this front brake setup....

Aloha,
Willy

MORE pix here, scroll down a ways....

Last edited by 2Loose; 12-08-2014 at 11:55 AM.
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Old 12-08-2014, 10:28 PM   #101
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Dad always had bikes, so I grew up learning to ride with my Dad and his brothers.

I love this bike, the '62FL, my first Harley Davidson and my third bike, a bike brand my Dear Old Dad rode for many, many miles and years.

After high school I was at UC Davis, in an Ag Machinery Engineering program, and paying my bills by working at the UCD fire station. There were always fireman around the station with bikes, so I got to ride a lot. I was staff, drove and maintained a '35 Dodge ladder truck (a short ladder truck, only went up three stories. No siren so I welded up headers with zoomies so they would hear us coming....)

But I also loved a 305 cc Honda Super Hawk, my first bike that I actually owned. After graduation I landed a great job in NorCal, when I bought the '63 Honda Super Hawk.

I had set it up off road style with high pipes, a bash plate, and really great knobby tires that loved to dance from side to side when out on the highway, age 21....

Then I sold the Honda, and bought a real good deal on a one year old '64 BSA 650 cc twin carb Lightning.

So I set it up off road style with high pipes, a bash plate, knobby tires that loved to dance from side to side when out on the highway, age 23....

Was invited to work running surveying and mapping at a Maui sugar cane plantation, brought the Beezah along, it was a great boonie basher, as the plantation connection lead to the ranches, where I got to go full moon midnight boonie bashin' with the ranch guys, way too cool!

But the guys I was riding with on the street were all riding Harley and Indian flatties, knuckles and pans (think 1967, a shovel was a rare sight back then...) !

I had a second set of rims with street tires, so it was an easy 10 minute adjustment back to street riding for an inspired 25 year old!!

So I got inspired to buy a '62 from a friend while on a long trip all over the big island with a bunch of friends in '67. I was riding the BSA, and a buddy was riding the '62. It was a bobbed ex Honolulu Police Dept bike. So I'm the second owner not counting the HPD. One Hawaiian guy then me.

I was working on the HD in the living room of a sugar plantation house, located in the mill town where I worked. And when I met my wife, she was amused but kept on smiling, and sorta tolerated my "chopper shop" until I got the '62 completely chopped the first time and out of the "living room". She wanted her living room back.

'Nuff fo' now....
Willy

Last edited by 2Loose; 12-08-2014 at 11:28 PM.
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Old 12-11-2014, 12:12 PM   #102
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Finally got 'er pulled apart, and the frame and tank are on the way to the media blast guy....

(This is a busy shop, there are presently my bike and my 55 Chevy, plus 2 trucks, a roadster, a 9 second drag strip car, and a couple other basic transport cars just being kept alive....)

All the parts lined up, motor and tranny on another bench....


My seat, I made a fiberglass seat pan for this, copied from an original Indian Scout steel pan that I had made a mold off of...


Motor, tranny, wheels, forks are all done. Now to do the rest of it and put it back together!
Aloha,
Willy

more PIX are here....

Last edited by 2Loose; 12-11-2014 at 12:24 PM.
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Old 12-11-2014, 12:23 PM   #103
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

I wish I didn't' work so much right now, but I gotta make hay while the sun shines. I wish I was there helping. Love this bike.
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Old 12-11-2014, 12:26 PM   #104
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Jaws, I stole the gas tank off the "P-Driver" yesterday when nobody was looking, gonna try to get a paint match today....

And the machine shop has the adapter for the front disk brake.
Wish I had access to a good lathe, I'd like to try my hand at turning that down myself!
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Old 12-11-2014, 12:41 PM   #105
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

You know you are welcome to anything at my house, parts, bike, cars, whatever. I wish I had a lathe too.
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Old 01-16-2015, 06:51 PM   #106
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Finally got some lathe time,
set up the large 3/8" disk to be cut for the rotor carrier first....


Then cut the 3/16" shoulder to fit the disk rotor....


Got a really good fit with the disk, and only cut the shoulder to 1/8", leaving a thicker piece backing
the rotor....


Flipped it around and started on the 3/4" piece to fit in the '62 Star hub....


Cleaned up and beveled out the weld while we were at it....


Then ran a series of increasingly larger drill bits in the center until it was large enough to get a
cutting tool in there, and took it out to get a snug fit on the Star hub....


Time for a check fit on the '62's front wheel....


Right side looks good too....


More later,
Willy
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Old 01-16-2015, 06:52 PM   #107
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

OK, now it's time to drill and tap for the disk on the disk carrier....

The bolts for the original Suzuki rotor are allen head, 8 mm, 1.25 thread.
There is also a 10 mm shoulder on the bolts that fits the 10 mm holes in the rotor, and locks
into the disk carrier an additional 2 mm before the 8 mm thread starts in the carrier.
My transfer punches are all US, but the 13/32" punch fits nicely in the 10 mm hole,
and allows me to accurately center punch the six holes.


Punched, drilled and tapped 2 holes opposite each other.
The tap is an 8 mm, 1.25 thread, so trying to find a starter hole size for the tap
was a bit of a problem. A 6.8 mm drill was spec'd, or 0.268".
A 17/64" bit was used, it is 0.266", just slightly tight for this tap,
But by using a good quality cutting oil, and working the tap through
the metal carefully, it went very well.


Drilled the center punches first with a small bit, I used a 3/32" on this one.
Then followed up with the 17/64" drill, then ran the tap through.


The disk carrier has not been countersunk yet for the shoulder on these bolts,
so flipped the rotor over and put the bolts in for now from the back side just to check it all out.


The bolts are a bit long, and looks like there may be some interference with the spokes.
But I need to get a 10 mm drill to countersink the carrier holes a bit for the shoulders
on these bolts, then I can figure the total bolt length I can get away with on this setup.


Just some pix of the 8 mm tap and the bolts themselves.


Here you can see why I need to countersink the 10 mm hole into the carrier
to accomodate that shoulder on the bolt....


Checking the backside bolt length against the spokes, need to be shortened slightly,
but the carrier needs to be countersunk first, with the rotor flipped back over
which will expose more thread. Want to run some ss acorn nuts on these threads.


Put the caliper on to check it out, looks good and clears the spokes.


When it is all setup and pressurized will be the final check.
Since the piston is on the outside, the floating caliper will move
away from the spokes as the pads wear down.


Here the bolt heads are exposed because the carrier holes have not been
countersunk yet, they will be flush with the rotor once the countersunk holes
have been drilled and the rotor flipped over to accommodate the flats on the bolt heads.


More Later,
Aloha,
Willy

More Pix Here....
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Old 01-17-2015, 12:03 AM   #108
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

You have been busy. Looks great!
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Old 01-22-2015, 03:22 PM   #109
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Countersunk the bolt holes on the rotor side with a 25/64" drill,
seemed to work well for the 10 mm shoulder on these rotor bolts....

Then two washers and a hex nut provided the correct height on the bolt threads
to shorten them for the acorn nuts....
Perfect fit....
I think this would look good on the spoke side of the brake rotor,
but unfortunately they were just a hair too close to the spokes, so will have to
just run the hex nuts....

The other alternative is to machine a spacer where this center hub fits
into the wheel's star hub to move it out just enough to have the
acorn nuts clear the spokes. I tried positioning the brake carrier
in many positions, but no matter where I put it, at least one or
more of the acorn nuts would hit a spoke and tilt the carrier slightly
preventing it from seating correctly in the star hub !
A thin spacer inside the star hub would correct that.
The rotor side looks great with the rotor flipped to it's correct side
and the bolts counter sunk into the carrier the correct depth....
Double checking everything for a good fit....
I want to run either flat washers or lock washers under these hex nuts to
bring them out to be flush with the end of the threads....

But they clear the spokes just fine....
Now to drill and tap the carrier for the 5/8" - 20 threads on the wheel bolts.
As that is a "special" HD thread, I have ordered taps that will cut that thread.

More later on the front disk brake...
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Old 01-22-2015, 03:42 PM   #110
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Back to the rest of the bike....

Tryin' to match the original red I used back in the late 60's on this bike.

Compared it to the red on my '58 Chevy truck, which is a GM Torch Red,
It's pretty close....
Think I'm gonna go ahead with the truck color

In the meantime, sent the frame, tank and rear fender off to the sandblaster....
I actually like that light gray color a lot !!

Yeah, that's my '55 Chevy Viking series 4x4 parts chaser....
I love this tank, want to do something special with the concave on the sides....
More Later....
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Old 01-22-2015, 04:28 PM   #111
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Nice work, it's coming along great. Could you shorten the acorn nuts a bit to get them to clear the spokes? Maybe shave the hex face a little, and depending how they're made, lose a touch off the dome too?
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Old 01-22-2015, 04:56 PM   #112
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Great work on the star hub Conversion.... I'll have to keep this in mind.
When it comes to Metric thread Drill size always og up 0.1mm... for example... M8 Call for 6.8mm.... go 6.9mm if you can. If you think about it... the points of the thread don't hold shit really. Will save you time tapping and remaking your work cause you snapped your tap going too tight.
Here is a real cool product instead of standard lock washers and Jam nuts.... I use this all the time now. Never failed me yet.

there are a bunch of vids,.... this is the first one I found:
https://www.youtube.com/watch?v=cDlmbMV9ICU

keep the updates coming


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Old 01-23-2015, 12:03 PM   #113
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Lester,
Thought you might like to see this photo of my '63 BSA Lightning.
Owned it from '64 to about 2000, when a local BSA collector finally
talked me out of it, he still has it in his collection, as well as a
Gold Star 500 I also had.
Aloha,
Willy
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Old 01-23-2015, 12:21 PM   #114
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Quote:
Originally Posted by Lester View Post
......Metric thread Drill size always og up 0.1mm... for example... M8 Call for 6.8mm.... go 6.9mm if you can.....
Good Comments, as I used a drill bit that was 0.002" under to hit the 6.8mm, I was tight from the get-go, and as I only had a plug tap, it was tight right from the beginning also! Going closer to the 6.9 spec would definitely have made it easier. But with a really good thread cutting lube, and hand turning then backing off every half turn, I got it through with no problems, and the bolts fit very nicely into those holes...

I looked at trimming the underside of those acorn nuts, and decided to look at it later, it can wait as I just want to get this project back on the road and ride it!!

I'm thinking that I'll just machine a spacer to lay in the star hub to get just enough additional clearance for the acorn nuts to clear the spokes. That I can do later on. Am fashioning the carrier for the caliper, will post pix as it comes along. Also starting the paint for the sandblasted parts.

As the wheel bolts are 3/8"-20, I don't have taps for that, asked around, none of my buddies do either, so I ordered a plug tap and a bottom tap, couldn't find a tapered tap in that size, from the mainland, should be here Monday or Tuesday, then I can cut the wheel bolt holes and bolt it up. Need to do that before I can really design the caliper carrier.

And two of my 4 wheel rigs have developed problems I have to deal with now, that always slows things down !!! A leaky th400 in my 58 pro street chevy truck, and a loud clicking noise from the stick shift in my 55 chevy gasser, it never ends !!!
Aloha,
Willy

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Old 01-23-2015, 11:24 PM   #115
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

It would if you were not a gearhead.
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Old 01-26-2015, 12:08 AM   #116
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

The taps came in, so I transfer punched, drilled and tapped one hole, and

it was a perfect fit on the star hub....

In my tool drawer I have two standard 3/8" taps, a 3/8"-16 NC that requires a 5/16" drill (0.3125") and a 3/8"-24 NF that requires a Q drill (0.332") and I could not find a reference for the drill size for this 3/8"-20 tap, so I tried a 21/64" drill (0.328") and the tap was tight on that first hole, but I got it done....
Since that first hole was really too tight for the tap, I moved up to a Q bit (0.328), I transfer punched the other four holes, and drilled the 1/16" centering holes.
Drilled the four holes with the "Q" drill bit and tapped them.
The taps felt right this time, not too tight or too loose.
These are blind holes, drilled roughly 1/8" deeper than the HD wheel bolt threads.
Ran the plug tap in first, then the bottom tap to run clean threads all the way down.
The bolts all go in perfectly, and go all the way in, no problem...
The bolts and holes matched up perfectly to the star hub on the 21" wheel I'm going to use!
Just a closer look, I should never have a problem with this....
Now to design and fabricate the bracket to mount the caliper on.

Willy

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Old 01-26-2015, 01:01 AM   #117
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Hold up on making any real changes to the legs on that AEE front.

The "new" frontend might have what you need on it. That is if you so chose to use it. Still awaiting it's arrival.
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Old 01-26-2015, 04:00 PM   #118
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Now to design and fabricate the bracket to mount the caliper on.
This is roughly the position for the caliper, up slightly, it's sitting on the disk now.


A rough sketch of what I am thinking, a bracket that floats on the axle to provide
vertical position, then a link to the old drum brake tab on the fork slider.
All cut from 1/4" steel.



I can't decide if that link back to the fork slider should be solid mount or make it floating.



Willy
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Old 01-26-2015, 04:40 PM   #119
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

The caliper floats on the bracket, doesn't it? I'd make the link solid - alignment-permitting, it could even be combined with the T-shaped caliper mounting bracket mounting bracket
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Old 01-26-2015, 10:14 PM   #120
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Quote:
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....... it could even be combined with the T-shaped caliper mounting bracket mounting bracket
Yeah, I think so, make that whole bracket one piece, maybe even put a steel dowel of some sort on the fork slider bracket so that part of the bracket can also slide into place.

Gotta think on that a bit more, start cutting cardboard templates and see how the fit, maybe even a sheet metal template out of some 20 galv I have layin' around.
Willy
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Old 01-31-2015, 05:55 PM   #121
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Put the front forks together, put the wheel and brake rotor on,
and propped up the axle so the wheel can spin....

Here you can see how tight this space is, 1"....
I got that rotor right where I want it !
AND, it spins true, no wobble at all....

The caliper looks good up here....

Maybe a little further back, almost touching the fork leg....

Or maybe it should go under the fork leg ??
It looks like the mounting bracket would be smaller and fit better in this location....
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Old 01-31-2015, 09:38 PM   #122
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

It looks better in person.
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Old 02-01-2015, 10:00 AM   #123
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Under looks cleaner.
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Old 02-01-2015, 10:21 AM   #124
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Quote:
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under looks cleaner.
+1.
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Old 02-01-2015, 04:31 PM   #125
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Quote:
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Under looks cleaner.
Yeah, I agree, and the bleeder is still on top, so no problems there. Now to just DO it!

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Old 02-02-2015, 01:25 AM   #126
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

You can do it!
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Old 02-02-2015, 11:06 PM   #127
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Been really busy, but found a little time today to cut some cardboard....


It fits in there really well, and I have the caliper's frame located where I can drill and tap for a bolt from the fork slider's brake lug directly into the frame:


Now to make this bracket out of 1/4" steel. Wish I had some stainless to do this with.
Willy

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Old 02-03-2015, 09:24 AM   #128
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

The front brakes are coming out real sweet. I am steal all this for my Pan... the drum brakes are a joke and I would like to ride a bit harder on our narrow curving roads.
Nice BSA! Should have kept it!

Cheers
Lester
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Old 02-03-2015, 12:33 PM   #129
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

When I first narrowed that long front end, there was no room for the stock front drum brake. But like you said, Lester, they just don't work worth a damn anyway, so I rode for years without that front brake. But now want a good working brake in front, and want to keep the star hub, so went this route. I think I am going to be fine with this setup. The rear juice drum brake works great, can lock up that rear tire if I want, but I try real hard not to ever lock that up !!!
Aloha,
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Old 02-04-2015, 01:52 PM   #130
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

The first step is to get the frame for the caliper correctly located,
and drill and tap a hole in it for the anchor bolt on the fork slider.


Decided I needed to be able to more accurately align the pads with the rotor, so I
pulled off the caliper but left the pads loaded in the frame, transfer punched the center of
the fork slider hole to the caliper frame after the pads were accurately lined up...


The hole in the fork slider for the brake is 7/16". So I used a 7/16" transfer
punch to mark the center of the fork slider brake lug on the caliper frame,
Then drilled and tapped it for a 7/16" fine thread, and bolted it up with a 1/4"
thick washer as a spacer, as the final caliper support down to the axle will be 1/4".
The two original holes in the caliper frame were 10mm fine, drilled them and
retapped them also to 7/16" fine.

I'm looking for some ss 7/16" fine thread allen head bolts to use on this, the cap screws are ok for now though...

Pulled a piece of 1/4" thick channel out of the scrap pile to cut the final piece.


There is a bit of a problem here though, as the fork slider brake anchor tab
is not in alignment with where the part that fits on the axle, so they will be two
separate pieces that will be aligned and welded back together.


It's gettin' there....
Aloha,
Willy
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Old 02-07-2015, 02:04 PM   #131
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Default Re: '62 Chop, 4th Rebuild in 42 years.....


Rough cut these two pieces for the brake caliper support
from some 1/4" scrap steel I had on the junk pile....
Left plenty of room around the edges to reshape as necessary....

The bottom piece overlaps behind the top piece, as the fit on
the axle is offset 1/4" from the fit at the original brake lug on the fork slider.

Fitted the upper piece to the caliper....

And transfer punched the three holes to get the centers...

Drilled with an 1/8" bit first to center the holes, then with a 7/16" bit....
It bolted up perfectly....

Another view....
The long center bolt will anchor it to the lug on the fork slider....
The chalk mark shows where I have to trim it a bit to get a better fit against the fork slider.
I'll do that a little at a time until I get the fit I want.

Now to cut the hole in the other piece to fit the axle,
fit the two pieces together, and weld them....

Aloha,
Willy

LINK to other pages on my site for the '62

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Old 02-08-2015, 12:10 AM   #132
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Had to keep trimming the bottom of that upper piece until I got a good fit
against the side of the fork slider and the brake lug....


This piece now fits snugly against the side of the fork slider when bolted up solidly....
And there is good alignment with the brake disk....


Looks good from the other side as well....


And the front wheel will still drop out with the caliper in place, a good thing....


Cut the 1-1/4" hole in the lower piece, put it on and aligned the two pieces, overlapping them....
And welded em' up....


Checked em' against my templates, this is working out well....


The other side, this is the side that faces the wheel....


Bolted everything up, and flipped the forks over to the correct side up, and it all looks great !
I still need to do some more grinding and polishing, then some paint, and that bracket is done....



I'm looking for a master cylinder, kinda old style looking, for the handlebars....

Aloha,
Willy
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Old 02-08-2015, 02:22 PM   #133
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Some fabriction going on, have to follow your build...
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Old 02-09-2015, 01:16 PM   #134
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

SG, I'm subscribed to both your build threads.

I have the vin of the Suzuki my front disk brake setup came off of,
went online and found it was a 1985 Madura GV700 V4, found
a caliper rebuild kit for it online and ordered it.

A 700 cc V4? Man, with 175 cc cylinders, with 4 valves per, that
motor must have been a screamer....

Now looking for a master cylinder for it.
Something simple and the older looking the better.
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Old 02-09-2015, 01:51 PM   #135
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

I like that you keep chipping away at this. Sometimes it really is only half an hour or so that you can get away to the shop for, and sometimes building up a bike takes a little while.
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Old 02-10-2015, 05:59 AM   #136
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Quote:
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Now looking for a master cylinder for it.
Something simple and the older looking the better.
I like the Honda CB750 master cylinder, it might work for your application.

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Old 02-11-2015, 02:01 AM   #137
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Damn, Willy you're busier than a one armed Paper hanger! Looks great. Love that Honda Master cylinder. Any more info on that? Year, model etc? Capacity?
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Old 02-12-2015, 12:35 PM   #138
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Yeah, I like that honda unit too. Wonder if that would fit on a 1" bar? A lot of those are only 7/8"....


Bought a quart of PPG, JAU Direct Gloss Acrylic Urethane in Torch Red.
Got my gun out and blew some red on the tank and rear fender.
Now we're gettin' back to the old color, I had originally sprayed this color in lacquer,
don't remember how many coats, but there were a bunch, each hand rubbed....

Ya don't wanna breath this stuff, so I did it in my carport, a very light breeze was flowing through
which made it perfect!
Later in the afternoon a little sunlight peeked in through the trees outside and lit up that red paint,
This pic just doesn't do this paint justice !!

The frame is not ready to paint just yet, but I had a little paint left in the gun, so I blew
that last bit on some of the frame tubes just for a look-see....
Yup, that's the color I remember....
I want to smooth out some of those welds before I paint the frame.


Aloha,

Willy

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Old 02-12-2015, 01:18 PM   #139
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

I found this one at an online bizz, www.vintagecb750.com .....



but I suspect it is only available in 7/8", have an inquiry out to them to find out.
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Old 02-12-2015, 01:50 PM   #140
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Well, as I suspected, it is available for 7/8" handlebars only....
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Old 02-12-2015, 02:10 PM   #141
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Hey!

That looks like color on the bike I have in my lanai!
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Old 02-12-2015, 02:28 PM   #142
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Hetooy Willy,

Your brake set-up blows me away.... sĺ sweet and all for a good old star hub too. CB750 MC.... the all aluminium one looks like its got enought meat on there to make it fit a 1" bar... After seeing your fab capabilities this shouldn't be a problem,
Dones the CB750 MC have a brake lite witch built in like alot of jap MC do???
I hate square brake fluid containers.

Cheers
Lester
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Old 02-12-2015, 03:55 PM   #143
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Willy,
I wonder if ya couldnt cut off part of the handle bar, slug it and reduce it to 7/8th's?
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Old 02-12-2015, 08:15 PM   #144
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Quote:
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Hetooy Willy,

Your brake set-up blows me away.... sĺ sweet and all for a good old star hub too. CB750 MC.... the all aluminium one looks like its got enought meat on there to make it fit a 1" bar... After seeing your fab capabilities this shouldn't be a problem,
Dones the CB750 MC have a brake lite witch built in like alot of jap MC do???
I hate square brake fluid containers.

Cheers
Lester
I think Lester has the right idea. Just ream it out a total of .125 At a .0625 radius that's not a whole lot. Unless the pinch screws are too close together.
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Old 02-13-2015, 12:06 PM   #145
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

been considering both options, think I'm going to get one, and just check out how much metal is there. If the alloy is weldable, I can built up the outside of the clamp with aluminum weld with my tig, and smooth it out, but cutting and welding in a 7/8" slug at the right point might just be a good way to go, done correctly I doubt you'd even see it when the MC is clamped in place.

Reaming the clamp to 1/2", I wouldn't have to take any metal out of the "belly" of each side of the clamp, start there and radius it from zero out to where the two sides of the clamp come together, leafing full metal thickness at the MC and opposite it, and use longer clamping screws.

OK, that's it, I'm gonna order one. Deal with it when it arrives.
Willy

PS, Lester, I don't know, will check that out when it gets here.

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Old 02-13-2015, 12:28 PM   #146
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Here's the posted desc. on that, it's a 5/8" bore, perfect for a single caliper, and does not have the brake lite switch:

Front Brake Master Cylinder Assembly.

Black body with silver lever. We had these manufactured with a piston size of 5/8", this will give your bike improved and more sensitive braking. These do not have a brake light switch similar to the OEM type. They are designed to look similar to the original CB750 master cylinders listed below.

Fits: Honda CB750K (1969-76)
CB750F (1975-76) Supersport,
CB750A (1976) Hondamatic

will also work on all other (1969-78) CB750 bikes but may look slightly different from the original stock type.
Part #: 08-0253

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Old 02-13-2015, 01:03 PM   #147
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

looking forward to see pics of the front end back on... dig that color!
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Old 02-19-2015, 08:23 PM   #148
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

These nice handlebar controls for the Suzuki disk brake I put on the front wheel showed up today.
Found this pair of early Honda cb750 controls, 5/8" piston bore, perfect for a single caliper disk setup....

I like the round style brake fluid reservoir better than the rectangular ones seen around lately,
and this set included the matching clutch lever....


The only problem is that these are for a 7/8" handlebar, I can modify the handlebars to have a short section
of 7/8" plug on each side where these will be mounted, or looking at them it looks like there is
enough meat in the side of the clamp next to the levers to do an offset bore, so that most of the
1/8" of metal removed would be against the side where the levers are.
It doesn't look like it would weaken it at all....
I might not be able to do that on the master cylinder though, it depends on how close an 1/8"
cut might get to the internal fluid channels. Need to check that out. There's a lot of "meat' here
though, maybe just take a 1/16" all around.
I'll fit it to a piece of 7/8" bar first to see how the gap at the screws looks...

Aloha,
Willy
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Old 02-20-2015, 02:25 AM   #149
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

The one in my pic I bored out to 1", no problems at all. It's only 1/16" either side. I shortened the levers too, they welded quite nicely with a TIG set for aluminium.
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Old 02-23-2015, 01:55 PM   #150
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Somebody once told me my rear brake looked a little newer than a '62, possibly an early shovelhead rear brake.

When I was fitting it to the "new" frame I had Denver's weld up for me many years ago, after pulling it off my '62 homemade hardtail conversion, it needed some work to get it to fit.

Can anyone tell me if this is a '62, or is it possibly a little later??



More Pix Here...

Willy
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Old 02-23-2015, 04:01 PM   #151
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

that's a 63 to 72 backing plate
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Old 02-23-2015, 05:16 PM   #152
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Willy,
I don't know if you use this little trick or not, but it might help someone out -

If you end up opening up the holes in the brake and clutch lever assemblies to fit your 1" bars, it helps to put some spacers (washers with a small O.D. work good) between the two halves of the clamp before you snug them up prior to milling or drilling. It will hold the concentric spacing correctly and help ensure that you don't remove anymore metal than you need to. If you can find a right sized uni-bit it makes for a real clean looking hole. I've done it this way a few times so I could use 7/8" hand controls or risers with 1" bars.
That set of hand controls that you've got (the H*nda ones ) look pretty good!

Geo.
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Old 02-23-2015, 06:50 PM   #153
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

I'll trade ya. Yours was on my bike. Mine is newish and is 58-62, made for starhub. Is your rear wheel a starhub like the front? If not then you will have to keep what you have.....and get the stuff for 67-72 Mid star hub

Go take mine apart and take what you want. I'm not in a hurry to get mine back together and I can get more parts later. What's mine is yours.
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Old 02-24-2015, 01:00 PM   #154
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Quote:
Originally Posted by old.wrench View Post
...... it helps to put some spacers (washers with a small O.D. work good) between the two halves of the clamp before you snug them up prior to milling or drilling. It will hold the concentric spacing correctly.....
Thanks George, that's a great idea. Thinking further on that same idea, what if I spaced it even more so it was 1" front to back, and 7/8" wide at the clamp lines, and only took out the additional 1/8" at the clamp lines, leaving a little extra meat in the clamp?
Or would it look odd?
Hmmmm...

Quote:
Originally Posted by JAWS View Post
I'll trade ya. Yours was on my bike. Mine is newish and is 58-62, made for starhub. Is your rear wheel a starhub like the front? If not then you will have to keep what you have.....and get the stuff for 67-72 Mid star hub

Go take mine apart and take what you want. I'm not in a hurry to get mine back together and I can get more parts later. What's mine is yours.
Yeah, it's the original '62 star hub back there, I had to modify the left side axle plate on the Denver's frame to take that backing plate, will check the '62 you have and see if it will work with my mods to the frame. I also drilled and tapped the rear boss on the wheel cylinder and plugged the front inlet hole as it was hitting the frame, you can see it here and compare to the pix above:


I had to elongate that brake anchor bolt hole so the bolt could move up and down slightly as the brake and wheel moved forward and back to adjust for the chain wear.

Also the front top of the backing plate, that ridge on it, was hitting the frame, so had to add some "clearance" to the frame....


Gotta run,
Willy

Last edited by 2Loose; 02-24-2015 at 01:14 PM.
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Old 02-24-2015, 01:06 PM   #155
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Quote:
Originally Posted by 2Loose View Post
Or would it look odd?
Hmmmm...
Yup!
You got talent and retirement.
Take the time to do it right, just like old wrench said it.
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Old 02-24-2015, 02:03 PM   #156
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

I know what you did. You opted for the wider brakes from 63-66 so you could keep your 62 starhub. After all, the stock front drum was not worth a shit for stopping. And you like to over engineer. Plus you were a dealer for aftermarket stuffs.
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Old 02-24-2015, 02:28 PM   #157
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Willy,
On boring out the handlebar holes in the controls - sure, you can space them a bit further apart if you want to. When you do that, it will really help if you can use a uni-bit in a drill press. The uni-bit will start it's self concentrically and cut true even though the hole that you are attempting to "open up" might be elliptical or not round, and it won't grab like a twist drill bit will. A nice vertical mill set up with a 1" cutter would be ideal for the operation, but most of us aren't fortunate enough to own one .

Geo.
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Old 03-12-2015, 12:22 AM   #158
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Found some time to work on this bike a little, have a different clutch control I like better than the first one I had, and it's for a 1" bar:


It's got an electrical switch built in, not sure what that's supposed to be for....


Got a 1" unibit, so I still need to bore out the Honda master cylinder bar mount, but there's a lot of "meat" there, it will be no problem....

Am also thinking of changing out the handle on the Honda master cylinder using this one, if I can get it to fit....



Not a very good pic, but this pressure actuated switch fits into the hydraulic fitting on the master cylinder to activate the brake light...


Meanwhile I still have not gotten the frame ready to paint. Weather's been horrible here, high winds and lots of rain, and my paint booth needs good weather, as it is partially open to the weather....

Aloha,
Willy


More Pix Here

Last edited by 2Loose; 03-12-2015 at 12:40 PM.
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Old 03-12-2015, 12:41 PM   #159
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Anybody know what that switch is for on the clutch control in the second pix from the top, above ??

As I'm gonna paint that part of the lever setup black anyway, maybe I can just cut that off, weld it up, grind it smooth, then paint it....
Willy
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Old 03-12-2015, 01:39 PM   #160
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

I don't know, but theres some safety features that my jap bike had.
The engine died if you tried to take off with the stand folded out.
I belive that you could have it running in gear with stand out if the clutch was pulled but it died when you let the clutch out.
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Old 03-12-2015, 02:04 PM   #161
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Hmmmm.....
Interesting....
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Old 03-12-2015, 02:20 PM   #162
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

I agree with Elffors, some bikes have a safety switch so that you have to pull the clutch lever before the starter will turn.
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Old 03-12-2015, 07:48 PM   #163
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

That makes perfect sense !

My wife's car is like that, step on the clutch, and the starter will work....
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Old 06-02-2016, 10:15 PM   #164
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

I'm finally back working on this bike.
I had a bad industrial accident last year, severely cut my left hand, severed some tendons, it's been a long recovery. Plus some of my 4 wheel rigs have been giving me nightmares, taking time I hadn't planned on giving them.

But finally got back on the '62, working the Denver's frame for final paint...


And prepping the tank and rear fender for some clear coat...


Will post more pix...
It feels good to get back on this project....
Willy
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Old 06-02-2016, 11:42 PM   #165
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

About Time!!!
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Old 06-02-2016, 11:51 PM   #166
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Love seeing this back on the front page!
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Old 06-12-2016, 06:59 PM   #167
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Well, I might be moving slow, but at least I'm moving....

Did some more prep work on the frame and tank and rear fender to get a better finish.....



Got yer shades on ?



More pix here
Willy

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Old 06-13-2016, 06:23 AM   #168
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Shades er on! ........Looks great Willy!
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Old 06-13-2016, 03:02 PM   #169
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Soon..very soon. We ride!!!
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Old 06-14-2016, 03:41 PM   #170
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Very nice! Like the dished tank!
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Old 06-17-2016, 01:05 PM   #171
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Am traveling for awhile, so it will have to wait until I get back....
I WILL get er done....
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Old 06-29-2016, 09:03 AM   #172
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

can't wait to see it finished
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Old 07-10-2016, 12:46 AM   #173
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Got a lot of family visiting right now, taking a lot of time, but it is enjoyable time, I wouldn't miss it for the world...
but got some time in on the bike today, fitting up parts and finding where I have to do a little more work off on the side to get 'er together...
but came up with this:

More Here

Aloha,
Willy
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Old 07-10-2016, 12:50 AM   #174
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Happy Days.
Solid Red is great look.
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Old 07-10-2016, 01:09 AM   #175
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Wish I could do some tasteful black and gold pinstriping though, just a little bit here and there...
Willy
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Old 07-10-2016, 10:07 PM   #176
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Cant wait!! Lets get to riging our chops!
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Old 07-14-2016, 12:57 PM   #177
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Got some parts cleaned up yesterday, gook and rust removed, and painted.
One was the tranny plate, had a little bit of time today, so snuck out to the shop and put the tranny in...

Don't like these bolts, so will get some new grade 8's and replace them....

Actually, the front ones are slightly too short, and do not fully engage the nylock nuts, interesting, as they did in the stock frame, so this Denver Mullins frame must use thicker stock for that front mounting flange. The local store did not have nylocks in the 3/8" fine (SAE) thread, which is what I want to use, and what the oem used. So I got longer grade 8 SAE bolts with grade 8 SAE hex nuts, and some SAE jam nuts to put on top of them. Will show pix when I change 'em...

Started working on the rear brake, all looks good, it was in good shape, was working just fine when I shut the bike down in 1990. I just got a rebuild kit from the local Napa store for this size cylinder, includes rubber cups, end covers, and a new spring. The old pistons are in good condition....


The wheel cylinder was a little rough looking inside, so got my small brake hone and cleaned 'er up...

Wish my insides looked this good !!

Put the rear brake parts together with the rebuilt wheel cylinder...

These are the same parts that were in the bike when I last rode it...
The parts to mount it in the frame needed some scrubbing and fresh paint...
Waiting for the paint to dry...
Willy

Last edited by 2Loose; 07-15-2016 at 12:37 AM.
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Old 07-14-2016, 05:10 PM   #178
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

progress.... me like!
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Old 07-15-2016, 01:55 AM   #179
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Here's a teaser,

more pix HERE
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Old 07-16-2016, 11:20 PM   #180
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

When I first put the Denver's Frame on the ground with the long narrowed glide it felt so right with my buddies pushing me around in front of the shop, that I just had to complete this project...
Basically just swapping out the frame and the gas tank, the rest is what I first did back in the late 60's...

More Pix Soon...
Willy\
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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:
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(^^^) 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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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
govmule84
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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
2Loose
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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
2Loose
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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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