no not a chainsaw

  1. dobbslc

    dobbslc Member

    Messages:
    5,428
    Location:
    Hertfordshire UK
    Nice work!
    Those rods look very long compared to anything modern!
     
  2. zeppelin builder

    zeppelin builder Member

    Messages:
    1,500
    Location:
    peoples republic of scotland
    add a big heavy cast iron piston long stroke
    high piston speed ,its a wonder they got past tickover speeds
     
    Rannsachair, slim_boy_fat and dobbslc like this.
  3. zeppelin builder

    zeppelin builder Member

    Messages:
    1,500
    Location:
    peoples republic of scotland
    good job i checked the rod i dont think it would have lasted heres some more pictures clearly showing a defect under my magnifier
    been reading about an old harley tuner
    Jerry Branch ,who developed the kr racers
    and he used to cut and weld rods regularily
    so il give it a go il pre heat and post heat,
    and i will use ,er 80 filarc 6513 which is almost the same as the rod its got nickle,
    iron ,manganese and silicon
    most of the people who have done it used er70s2 wire nothing exotic
    20200726_111501.jpg
     
  4. zeppelin builder

    zeppelin builder Member

    Messages:
    1,500
    Location:
    peoples republic of scotland
    heres the conrod from the start first indication of a crack
    then a bit more cleaning and dye pen
    next excavation and more dye to get it all oot
    next degrease and pre heat to 200c weld using 1.6 pz6513 on completion peen weld put in preheated oven and bring down slowly
    blend weld toes warm up and soak in dye
    no visible defects

    as i have a dirty great DC magnetiser i thought id do some more ndt namely Mpi dc can also show subsurface defects

    so rods were coated and i sprayed them with the developer in both planes and happily i had no indications

    checked the rods for true then built up the crank
    welded up the cam followers with haynes ultramet £££ and profiled to same as 1 good one
    set up the cams all 3 of them
    them sorted out and motored the oil pump to check
    so bottom end all built fingers crossed
    top ends coming soon its originaly 550cc
    but it will be just short of 600 with the 2mm overbore 20200724_164646.jpg 20200726_111501.jpg 20200727_092736.jpg 20200727_093620.jpg 20200727_125130.jpg 20200727_162252.jpg 20200727_163529.jpg 20200728_100644.jpg 20200727_125503.jpg 20200728_160137.jpg
     
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  5. zeppelin builder

    zeppelin builder Member

    Messages:
    1,500
    Location:
    peoples republic of scotland
    20200729_182310.jpg 20200729_181056.jpg 20200729_181111.jpg got the modded Kubota d722 pistons and rebored barrels back tonight excelent job
    il put it together sans rings tommorow and chuck in some blue tack to check squish clearances and check top ring dosent run out of bore on the breathing side
     
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  6. zeppelin builder

    zeppelin builder Member

    Messages:
    1,500
    Location:
    peoples republic of scotland
    fitted up the pistons and had to chamfer the tops to suit the chambers ,it worked out well and the top ring is safely out of danger
    there is a couple of mm above clearance
    ive removed the expanders behind the oil control rings to give it a bit more oil
    the pistons protrude about 7mm at tdc so will give it a bit more compression and squish
    its all nice and free too so thats a good sign

    one of the exhaust valves was a bit short so i tigged about 5mm on the end with 309 and gave it a dollop of stellite

    next is overhaul the schebler carb it looks pretty simple and redneck proof only bad bit is the old cork float
    20200730_112128.jpg 20200730_110143.jpg 20200730_154811.jpg
     
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    Screwdriver, Cato, EBME2 and 2 others like this.
  7. zeppelin builder

    zeppelin builder Member

    Messages:
    1,500
    Location:
    peoples republic of scotland
    the old cork float looked a bit past it so i soldered a new Tecumseh brass one to the hinge part , bike is together and runs very crisp ,tickover is a bit unreliable due to wear in the butterfly spindle , so thats another job bushing and reaming the new parts
    just addressing all the wear on linkages
    we got another wheel with wired on tyre so m gaurd which is not original will need modded And forks will need overhauled and spindles freed and greased 20200731_065550.jpg 20200804_141358.jpg 20200805_184455.jpg 20200805_153455.jpg 20200805_184455.jpg 20200806_154717.jpg
     
  8. Screwdriver

    Screwdriver Member

    Messages:
    6,476
    UK London
    Wow. That's some seriously impressive restoration there. :thumbup:
     
  9. zeppelin builder

    zeppelin builder Member

    Messages:
    1,500
    Location:
    peoples republic of scotland
    heres the matching wheel
    had to notch the gaurd and pull it in to a suitable radius , shorten the stays and stand its nearly there im goint to shorten it at both ends and relocate the stand clip its been a lash up made from two ,got the bits for carb from sweden , and got the forks freed and lubed so another leap forward
    so much for itl take a week thats a month so far
    gonna be a sweet wee bike ,
     
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    Cato, Rannsachair and Migmac like this.
  10. Migmac

    Migmac Forum Supporter

    Messages:
    4,401
    Location:
    Kintyre. Scotland
    Think I recall you saying it was going to be a quick job:laughing:
     
  11. zeppelin builder

    zeppelin builder Member

    Messages:
    1,500
    Location:
    peoples republic of scotland
    IMG-20200807-WA0005.jpeg 20200804_163427_2.gif 20200804_163427_1.gif 20200810_113242.jpg 20200810_113242.jpg went to fit the new carb spindle and bushes
    and check the float height , turns out the float was full of petrol and sinking , put the float in a glass full of near boiling water and was rewarded by a fine jet of petrol in my face this showed up a bad seam joint which was fixed with a quick remelt and some bakers fluid
    its coming on near complete soon finished the front gaurd and stays so its make a rudimentary wiring loom and try and incorporate an electronic dynamo regulator
    then i will do a few miles on it and fine tune it
     
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  12. zeppelin builder

    zeppelin builder Member

    Messages:
    1,500
    Location:
    peoples republic of scotland
    had a ride on it very smooth and id sah it wants more advamce thats squish for ya
    miles more effiecient , hate them twist grip contols tho like wringing an old dishcloth


    only fault is oilpump leaks like a sieve , jb weld amazingly did not cure it donald , so timing cover off to get to one screw
     
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    Rannsachair likes this.
  13. Tifa

    Tifa Member

    Messages:
    39
    Location:
    Shropshire
    Wow!!!
    Late to thread...but now subscribed!
     
  14. zeppelin builder

    zeppelin builder Member

    Messages:
    1,500
    Location:
    peoples republic of scotland
    20200812_191216.jpg 20200812_102203.jpg 20200812_102138.jpg fitted brand new bronze bodied oil pump no more oil leaks , replca,bosch lighting and horn are very poor quality rear light had a dead short as no insulation on the live spade and fancy klaxon shows open circuit on its terminals ,,need further investigations
     
  15. zeppelin builder

    zeppelin builder Member

    Messages:
    1,500
    Location:
    peoples republic of scotland
    horn was an easy fix , someone had nicked the innards , managed go get a thirty bob chinese one inside though
    took bike out for a ride but after stopping with the back brake it refused to move forward , went back wards ok so stripped the drum off and there was a pair of brake shoes that somebody had made out of steel
    only thing was there was no return spring on the cam side ,more khaki paint was evident
    too so probably some field repairs
    il fit a spring and it be ok
    its having a problem with random flooding
    and ive tried everything i think the float is fouling inside the carb
    so im awating a needle and float from over the pond
    and that should be it done 20200814_104059.jpg
     
    addjunkie, Migmac and Rannsachair like this.
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