Double Trouble

[John H]

The engine plates are finished. Maybe a bit gaudy but in time will dull so I'll live with it.
The powder coater is closed until ?? so will keep working on other parts. Maybe tomorrow, the fuel pump.

IMG_2296.JPG (241.64 KiB) Viewed 28966 times

IMG_2297.JPG (238.65 KiB) Viewed 28966 times

[John H]

Nice surprise today when the powdercoater called and said the frame was ready for pickup.

IMG_2324.JPG (233.41 KiB) Viewed 28960 times

I can now install the Paul Martin master cylinder and make the brake arm to link to the brake pedal.

IMG_2322.JPG (192.1 KiB) Viewed 28960 times

[John H]

All holes in the frame have been cleaned of powder coating. Bearing races installed in the steering head as well as bearings fitted. I don't think the frame was made for this Ceriani fork set as the upper race that threads onto the stem ran out of threads before the proper drag on the bearings were met. So the stem was dropped .035" and a shim added. The locking crown nut was bottoming on the stem before it locked the tree against the upper bearing race. So another shim had to be made to correct this.. I know it all sound a bit anal but right is right, wrong is wrong.
The steering damper knob and parts are missing and were never very effective. If I had any intentions of ever racing this bike it would get a hydraulic steering damper immediately. It would look nice with the damper knob there wouldn't it.
I scored another early style Hilborn 150-0 fuel pump that is in great shape so will replace the old corroded unit.

IMG_2335.JPG (219.73 KiB) Viewed 28936 times

[John H]

Yard work first?? I finished the rear wheel chain adjusters. Nothing fancy but functional. While looking for a box of parts for the Z1R I found the missing exhaust pipe for the Triumph. Didn't find the box of parts but also found the extra Routt cylinder barrel for the Triumph as well as some rods and extra pistons. This is the damaged 800cc cylinder. It may become a donor for a 650cc race motor by re-sleeving it.

IMG_2364.JPG (223.67 KiB) Viewed 28920 times

[John H]

Still gathering engine parts, which will take some time so for now just I will concentrate on things like making chain adjusters. These were machined from 1/4" SS plate then welded the threaded rod to it. the blocks are aluminum.
The axle is from a Kawi 900 that had to be shortened by one inch. That's it for now.

IMG_2370.jpg (205.98 KiB) Viewed 28875 times

[John H]

Engine #2 got the final welding and cleanup. The 1/4" thick reinforced plate was surfaced to give a trued surface for aligning
sprockets. Engine #1 will get the same treatment when it's torn down.

IMG_2402c.jpg (174.87 KiB) Viewed 28848 times

[John H]

Did a mockup today to help make a schematic for plumbing and wiring. Different size lines are used for nitro than gasoline. Though it's not likely this bike will ever see a big load of nitro again I'll still plumb it that way just in case. All the fuel lines will be run first. That's 2 lines to the pump, one line to the barrel valve, 4 lines from the barrel valve to the nozzles then 2 bypass lines to the fuel tanks. Last will be a high speed bypass from the pump to one or both fuel tanks and vent lines from each fuel tank that will go to a spill proof bottle.

IMG_2421 copy.JPG (185.67 KiB) Viewed 28805 times

IMG_2425 copy.JPG (181.88 KiB) Viewed 28803 times

[John H]

Mocked up a different rear fender than originally came on the bike. A support brace over the top needs to be strong so it can be used to also lift the bike on its stand. I need to be cautious here since I can't tell where the center of the tire will be until the engine, clutch and drive sprockets line up.

IMG_2435 copy.JPG (218.96 KiB) Viewed 28754 times

[John H]

All four exhaust pipes have dents I'm going to try and remove.
Not sure this will work but I machined a trailer hitch ball down to a 1.650". That is the I.D. of the pipes.
I cut the excess off and welded it to a chain to the ball which will then be pulled through the pipe.
Haven't finalized the power source but thinking of using the handyman jack which is 4' tall.

IMG_2439 copy.JPG (185.92 KiB) Viewed 28718 times

[John H]

Well that didn't work very well. I turned the ball so it would have some clearance in the straight section of pipe but when it came to the curved part it got stuck. I heated the pipe to a red but where the ball was in contact with the tube it wouldn't turn red, and it wouldn't budge. I'll make a few balls of smaller diameters and increase the diameter until it removes the dents and hopefully doesn't get stuck again.