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Old 02-24-2020, 03:29 PM   #41
Thunderbird
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Default Re: 41 el

it was chlorinated additives in EP oil and hypoid gear oils as used in differentials that attacked phosphor bronze bushes so in that instance you're looking at gearbox oils AND I don't know enough about these lubes to know if they are still the same additives; anyone?
I use either straight 50W motor oil or semi fluid grease with a dash of motor oil in my unit gear boxes.
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Old 02-24-2020, 06:24 PM   #42
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So, been at it since I came home from work.

Had a delivery of parts, which was exciting, boring parts first got the throttle part of the link carb, plugs, and a front wheel axle + parts. At this point my night got a whole lot more fun. So, I ordered new cups and races, as the old roller ones are smaller, don't fit my new bearings and the like.

This is where the fun began. The old cups really didn't wanna play ball, I used a bit of heat, staked them with an 8 lb hammer for a good hour, the 'staker' was reground over and over and over on the 6" wheel and was folding like toffee.. Bottom cup came out with a wince and a fuss.. top one.. oh no... no fun here to be had friends. After getting tired, mentally and physically from a long day and the like I started to gamble, and, where the 'staker' had peened the hammer slipped past it's girth and smashed said thumb into the neck of the bike.

I thought I'd broken it I shan't lie.. school boy error, thumbs black 3 pinches and bruised and swollen. It's okay but a little tender. At last got the cups in.. bottom bearing won't go down to the bottom of the neck.. cut up and old exhaust, used said old cup and hit with said 4 lb hammer till snug. Got the front wheel and axle buttoned up.. a problem quickly emerged, the new cups and bearings were a good 60mm taller minimum. So you ask? what's the issue. My crown nut was binding with no neck thread to be shared, in turn, meant I couldn't get said top tree or anything bolted down.

Tried to turn the crown down, destroyed two of my old mans tungst carb tools. I had the brain wave with a bit of measuring, hacksaw the length off the bottom and turn it nicely(already turned the step on the top down bigger to sit more into the top clamp.

Ended up working a treat, Haven't got a photo of it but it's all buttoned up and I've used the piece I cut off and turned it to lock down the top nut.

Pics of tonights shenanigans. Had a fair bit of help off the old man tonight, his engineering help was much needed as those nuts are like as tough as the titanic.

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Old 02-25-2020, 11:20 AM   #43
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Default Re: 41 el

Very nice! Hope your exams went as well as this build!
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Old 02-25-2020, 03:53 PM   #44
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Doing little bits tonight, not worth a photo, rear brake switch, finishing my spark plug wires. I have a little issue that my front star isn't tightening all the way up to the point there's no play. So; from my quick surmise, the bearing in there (bought from somebody) is a little too wide. So to accomodate will turn the spacer down a little to pull it up.

Also getting my pipes ready to mount;

Pipe dreams.. getting the rear to sit in the squish is a pain in the ass properly.. any advice from you experienced folk would be grearly welcomed.

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Old 02-25-2020, 03:54 PM   #45
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Very nice! Hope your exams went as well as this build!
Thanks man, they went fairly okay too!
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Old 02-25-2020, 09:12 PM   #46
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Looks like the lower front cylinder pipe angle might be a little low for one and you could try a block off wood with a heavy hammer straightening out the angle a bit and the tab on the squissy looks like it's a bit bent. Straightening may lower it thus giving you a more parallel line. Could also use a bit of high temp silicone to hold them together.

Coming together crazy fast though and did I mention I really like this bike and style.
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Old 02-26-2020, 01:37 AM   #47
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the elephant in the room : what's the flattie going for /$.
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Old 02-26-2020, 03:29 AM   #48
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Default Re: 41 el

yeh that squish pipe is a pain in the ass, but I find it more pain in the ass sliding the front in and out. the rear piece is not too bad...
I find it that to slide the front in you have to rotate the squish clock and anticlock wise and up and down to make it slide in.

i use brute force and a lot of swear words. usually works lol
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Old 02-26-2020, 01:54 PM   #49
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yeh that squish pipe is a pain in the ass, but I find it more pain in the ass sliding the front in and out. the rear piece is not too bad...
I find it that to slide the front in you have to rotate the squish clock and anticlock wise and up and down to make it slide in.

i use brute force and a lot of swear words. usually works lol
My squish is very old and a bit "slack" it's going to need some hammer time loving to get it snug again.. no wonder I was fighting a losing battle! was like trying to turn a small vessel at sea! haha.
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Old 02-27-2020, 01:46 AM   #50
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I've chopped. lengthened, bought two squish pipes to make one work, even buying an OE squish pipe thinking that HD must have got it right.
Sometimes you just have to be a beast to get it to all work.
Get the fit, get the line and if that means 'massaging' the inner part of the pipe/muffler to clear axle, frame or mounting bolts; so be it.
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Old 02-27-2020, 03:26 PM   #51
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I've chopped. lengthened, bought two squish pipes to make one work, even buying an OE squish pipe thinking that HD must have got it right.
Sometimes you just have to be a beast to get it to all work.
Get the fit, get the line and if that means 'massaging' the inner part of the pipe/muffler to clear axle, frame or mounting bolts; so be it.
Ye, I feel the weld may be on the cards for me too. Mines damn old the pipes are 50 years old, braised the old fishtails on the pipes, old school at it's best haha. Waiting on male oil connectors for the pump and case and the bolt that goes under the genny. I'll be ready to start her then!
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Old 02-29-2020, 12:53 PM   #52
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I've hit a small conundrum.

I can't get the right front motor mount bolt in for love or money. I've taken the others out, and it's that silly shouldered bolt.

Any simple tips always welcome!! Except for that, I've got my clutch all set up, bought some nice chain and quick links, lightly filed a relief in the clutch arm so it was a pressed fit i.e never coming out ever again. Once I bolt this motor down properly, it's just genny relief for the bolts. Except for wiring that's that!!
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Old 02-29-2020, 03:17 PM   #53
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Default Re: 41 el

Start with that one, and see if the others won't slide home. If you can't get the bolts to drop in, something's fucked up... cases aren't matched or frame is tweaky or something else.

Ain't choppering great?
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Old 02-29-2020, 04:06 PM   #54
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Start with that one, and see if the others won't slide home. If you can't get the bolts to drop in, something's fucked up... cases aren't matched or frame is tweaky or something else.

Ain't choppering great?

Haha, certainly is sir! There were 4, albeit loose in the frame holding said engine down when I got her, so I know it'll go back in there. Must be a bloody hair out!

All in the name of fun..
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Old 03-01-2020, 01:16 AM   #55
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is the motor sitting flat, do you need to shim it?
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Old 03-01-2020, 01:37 PM   #56
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is the motor sitting flat, do you need to shim it?
Already done dude! I'm the cause and problem to my own demise, I put the belt on to line my tranny up.. you can imagine why I can't get mr 4th bolt in hah.
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Old 03-02-2020, 12:44 PM   #57
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Default Re: 41 el

Two things, 1) silly shouldered bolt. No. normal 3/8'' bolts. 2) front bolts are installed from bottom. A slight increase in clearance from threaded area in engine tab. Also allows bolts and there for engine removal with out generator removal.
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Old 03-02-2020, 02:38 PM   #58
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Two things, 1) silly shouldered bolt. No. normal 3/8'' bolts. 2) front bolts are installed from bottom. A slight increase in clearance from threaded area in engine tab. Also allows bolts and there for engine removal with out generator removal.
Yeah I've got them in now! was a right pain in the ass though! haha.
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Old 03-03-2020, 02:41 PM   #59
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Very little to update.

Clutch is all set up. Genny is on, I had a nightmare getting the genny on, long story short, made the bolts to fit it, but just couldn't get them to start. Used a tap to bite a little thread, worked and on.

Was messing earlier and found the head oiler lines are in the way of the M35 throttle assembly, as in, the throttle is only half opening. Upon closer inspection, said oil line to my left head wasn't fixed, just sat in there, snug, but not braised or anything else.. so bending it currently to fit around the throttle arm, and fix up. Except for that, just need to get the front pipe on and bolted on. Squish isn't at all playing ball so it's going to get some tough love. It's OEM Harley and fits like total ass.. All I need then is to fill her full of oil, get her running and tighten everything!
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Old 03-05-2020, 04:52 PM   #60
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So,

Into the final stretch. Found out why she won't start. No spark at all. Probably due to the top motor mount and not a good earth... that will be a story for another day.

Just starting to finish things up, front 3rd piece of the exhaust, after my tribulations and a borrowed pair of hands was bent to the angle any godly man on the planet would like, exhaust paste and brackets later it's on there like swimwear and secured. Last major headache (He says with confidence!!! ha) out of the way.

Few pics of my clutch chain and links which I put together, works great, Machined down crown nut which claimed the life of 3 tungst bits.. VERY HARD. And finally, my turned lock nut cover complete with coin. Better than looking at a thread and what not.






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