Crankshaft is back from grinding, but still have to clean out the dirt trap.

Fork stansion's have been polished and clear coated with 2K clear paint.

The crank sludge trap, was FULL of dirt!!

To remove the retaining plug, the punch mark was drilled out, then a slot was made in the plug, by drilling a series of 3mm dia. holes, that were worked until there was a slot. A large flat screwdriver bit was driven in to the slot. It would have helped to heat the plug up, to free up the thread locking compound. With a lot of effort on the socket wrench, the plug final came out. The the top crank bolt was removed, as it secures the sludge trap. Then the sludge trap was tapped with a M16 Tap, for say 3-4 turns, and an M16 Bolt and nut threaded in. When the nut was tightened, it drew the sludge trap out of the crank.

The dirt was then manually extracted from the cavity using a screwdriver, then a large twist drill, around 19mm Dia. The crank was then washed in paraffin, and eventual vapor blasted to remove all remnants of the carbon deposit's. The sludge trap was also cleaned in a similar way.

Here are the new taper roller bearing's and dust cap's for the steering head bearings.

Another view of the steering parts.

Tightening the fork stanchion stud's with Locktite, using the 2 Nut technique.

Locktite being applied to the stud's as a thread lock, as this is a safety critical item.

Parts of the forks.

Swing arm, pivot components.

Finally the swing arm is in!

Taking shape.

New Parts and Others

The frame and 28 other bit's are back from powder coating. Thank you Brett for organizing this!

The first assembly to be put together is the swing arm, here it is with some of the new bushes, spindles and sealing rubber rings. First the grease nipple holes were cleaned up using a 1/4" BSF tap. Then the bush housing's were cleaned of powder coating using a high speed air grinder with a slotted attachment with some 80 grit sand paper in it. Then a threaded rod and washer's were used to press the bushing's in to the housing. The bushes were then reamed out using adjustable reamer's to exactly fit the spindles. Then the grease nipples with fiber washer's were fitted.

                                                              

Some pictures of part's procured for the bike. It turned out all the expensive stuff was missing or worn out.

The barel has been powder coated, and all over spray area's cleaned up. Still have to finish honing it, and insert tapper guide blocks.

 

The crankshaft has been ground 10 Thou undersize, and new bearing shell's fitted. Clearance is 0.03mm, and new blots and nut's are yet to be fitted. Rods must still be finally polished to remove all scratches, then shot peened to stress relieve. We will also make some attempt to balance them. The crank oil strainer, still has the be removed and cleaned. This will involve some drilling and destruction of the existing plug. the crank grinding cost R260 Rand.

Engine Cover After Polishing and Some Things Done To The Frame

One of the side cover's after careful sanding using increasing grits of sand paper from 120# to #1000 before buffing, using two grades of compound.

A new tank mounting bracket is fabricated to replace the existing one that has been cut off with an angle grinder and 1mm cutting disk.

Dents in the frame are filled up with brazing, then ground down with an angle grinder and finished off with a 120# sanding disk.

 

The side stand lug, was broken off, and the remnant's removed with angle grinder cutting disk, and heat. A new bracket has been procured and will be welded on, once the correct angle can be determined.

More parts

Before and after shots of the air cleaner, after vapor blasting.

Before and after shots of the crank case, after vapor blasting

Two screws we had to make, on the carburetor manifold.

Loos part's going off for Cadmium plating.

We have had to take apart the tank so that we can get all the rust out! And fix all the rust holes! Not looking forward to this one.

Side cover undergoing sanding step's. At each grit level, all traces of mark's must be gone. For deep marks the process starts with a body file.

More before and after on crankcases after vapor blasting.

Some more parts after the vapour blaster!

Rocker Cover's after vapour blasting

Movie Star

It's so awesome it was chosen to be used in the move "Last Man Standing" :P