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Old 10-29-2011, 03:08 AM   #21
S.G
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Default Re: Kustom 1959 pre unit by Angry Monkey Motorcycles

Nice build, love those make everything yourself threads
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Old 10-29-2011, 08:17 AM   #22
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Default Re: Kustom 1959 pre unit by Angry Monkey Motorcycles

Super cool project and awesome workmanship! Have a '60 t120 in the the corner thats slightly cut up but mostly there. Great ideas
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Old 10-29-2011, 10:56 AM   #23
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Default Re: Kustom 1959 pre unit by Angry Monkey Motorcycles

Thanks for the comments guys!

This build gets a shock on the springer front end, which required moving the headlight. I like the headlight to be nice and low, so I made up a 10 gauge bracket to go around the shock to keep the light low. The bracket allows the headlight to be adjusted for vertical aiming too.



One of the issued I continue to run into with pre units, is when previous owners use improper inner primary spacers, or leave them out altogether. The result is, when they crank down the foot-rest nuts, the inner and outer primary covers get cracked, distorted, or broken out altogether. This inner primary had the footrest stud boss broken off completely, and the outer cover was puckered, with radial cracks. I tig’d up and smoothed out the outer cover. On the inner cover, I welded in a boss that went all the way from where the outer cover seats, to the inner motor mounts. The boss I put in there is also much wider than stock, to give better leverage to keep everything straight and true when the full weight of a rider is on the pegs. There is no way, now, to get the spacing wrong either.

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Old 10-29-2011, 11:04 AM   #24
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Default Re: Kustom 1959 pre unit by Angry Monkey Motorcycles

It's gonna be 30+ pages of pure motivation... Thank you Sir!!
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Old 10-31-2011, 10:42 AM   #25
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Default Re: Kustom 1959 pre unit by Angry Monkey Motorcycles

Great to follow along as always. Subscribed.
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Old 10-31-2011, 11:14 AM   #26
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Default Re: Kustom 1959 pre unit by Angry Monkey Motorcycles

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It's gonna be 30+ pages of pure motivation... Thank you Sir!!
Well, this one will probably be a bit more condensed, but thanks

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Originally Posted by Rotten Egg View Post
Great to follow along as always. Subscribed.
Thanks!

This is just a post to show you the type of client I have here. This chap is pure class. He visited a distillery in Bundaberg, Australia, and he went to the trouble to buy me a bottle of their rum as well as having a couple of classes engraved, then shipped the lot to me. Just so you know, this rum is super smooth, definately the best rum I've ever had. If you have the oportunity to try Bundaberg rum, you should.





Now, back to the bike stuff. Since I used a BNR belt drive (that will not fit under the stock cover) I made a ¼” aluminum spacer to go between the inner and outer primary cover. It’s another one of those things that loks like it was born there, and no one will probably ever notice.

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Old 10-31-2011, 12:24 PM   #27
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Default Re: Kustom 1959 pre unit by Angry Monkey Motorcycles

dan great job as usual bud
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Old 10-31-2011, 02:33 PM   #28
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Default Re: Kustom 1959 pre unit by Angry Monkey Motorcycles



You're not wrong Dan, it's a nice drop.
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Old 10-31-2011, 03:22 PM   #29
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Default Re: Kustom 1959 pre unit by Angry Monkey Motorcycles

Dan, Band saw, belt sander to make it fit??

I love rum.......

Best,
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Old 11-01-2011, 04:41 AM   #30
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Default Re: Kustom 1959 pre unit by Angry Monkey Motorcycles

How did I miss this???? Dan, loving every post on this thread...keep it up!!.
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Old 11-01-2011, 10:12 AM   #31
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Default Re: Kustom 1959 pre unit by Angry Monkey Motorcycles

Quote:
Originally Posted by undead View Post
dan great job as usual bud
www.thefactorymetalworks.com
Thanks Lucas!

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Originally Posted by sarnian View Post

You're not wrong Dan, it's a nice drop.
Let's see, old Triumph parts-Check! Empty Bundaberg rum bottles-Check! Have you been sneeking in my garage at night? HA!

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Dan, Band saw, belt sander to make it fit??
Yes, and Yes, as well as a jigsaw (with a new swiss blade) for the inside cuts.

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Originally Posted by Rob Axel View Post
How did I miss this???? Dan, loving every post on this thread...keep it up!!.
Thanks Rob!

Since this bike is a “generator” model, I used an Alton Alternator, which requires a decent size battery. So here is the 10 gauge battery box.


This pic shows the mount tab for the fuse holder, and the two studs will hold a quick-connect so a battery tender with the corresponding plug can be quickly/easily connected if the bike sits for any amount of time.


This is how the chain guard turned out. To meet Aussie specs it has a length requirement that has to comply with.
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Old 11-01-2011, 10:24 AM   #32
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Default Re: Kustom 1959 pre unit by Angry Monkey Motorcycles

Dan ...love your work! You my friend work way to fast!
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Old 11-01-2011, 11:00 AM   #33
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Default Re: Kustom 1959 pre unit by Angry Monkey Motorcycles

Damn fine work Dan this is gonna be sweet!!!! Bet that rum taste a little better than my Captains.
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Old 11-01-2011, 11:15 AM   #34
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Default Re: Kustom 1959 pre unit by Angry Monkey Motorcycles

Dan, what's that ink called you use to mark you metal work to scribe onto? I've used it before but I can't remember what it's called and I need to get some.

Cheers Dan.
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Old 11-01-2011, 11:41 AM   #35
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Default Re: Kustom 1959 pre unit by Angry Monkey Motorcycles

Quote:
Originally Posted by Ironsled77 View Post
Dan ...love your work! You my friend work way to fast!
Thanks!

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Damn fine work Dan this is gonna be sweet!!!! Bet that rum taste a little better than my Captains.
Thanks! And yes, the Bundaberg is indeed good stuff

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Dan, what's that ink called you use to mark you metal work to scribe onto? I've used it before but I can't remember what it's called and I need to get some.
It is machinist layout dye (or "marking blue"). It works tons better than sharpies if you need an accurate mark.

Cheers, Dan.
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Old 11-01-2011, 11:54 AM   #36
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Default Re: Kustom 1959 pre unit by Angry Monkey Motorcycles

I think it might be called "Engineer's Blue".

D.
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Old 11-01-2011, 12:00 PM   #37
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I think it might be called "Engineer's Blue".

D.
Engineer's blue is different, it is an oily, non-drying blue, used for checking gear teeth engagement, and other fitment issues. But the terms are easily, and often crossed up.
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Old 11-01-2011, 12:13 PM   #38
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Default Re: Kustom 1959 pre unit by Angry Monkey Motorcycles

why not go magneto and rid the clutter of that battery box hanging over the trans?
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Old 11-01-2011, 12:32 PM   #39
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why not go magneto and rid the clutter of that battery box hanging over the trans?
It is magneto powered. That's not the issue. No one likes a batteryless bike more than me, but this motor is a "generator" model, and I was set on using a modern, 12 volt charging system, while retaining the sexy, Generator primary cover (what's left of it anyway). The Alton alternator was my best choice, and as such, it has to have a substantial battery to function properly. I know I could have used the Lucas 6 volt system, or used a 12v converter on a Lucas gennie, but this bike is going a looooong way to its new owner, and I was not willing to roll the dice on a rebuilt or converted Lucas gennie. Tough choice, but it's made now.
Cheers, Dan.
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Old 11-01-2011, 12:59 PM   #40
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The Alton alternator was my best choice, and as such, it has to have a substantial battery to function properly.
why does an alternator NEED a battery if all its running is lights? I'm not familiar with the Alton products...
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