Topic: Crash the rebuild (Read 4181 times)

hogasm · « **on:** February 22, 2009, 10:33:36 PM »

This has been a long time in coming. Have had all the parts to build tis bike for awhile, just need the time to start the build.

Started with a 2002 ultra with a little tank modifying

hogasm · « **Reply #1 on:** February 22, 2009, 10:37:58 PM »

Changed the frame just a little. Painted it marbled brandy wine. Needed to install the new swingarm and 200 tire to make a rolling chassis

hogasm · « **Reply #2 on:** February 22, 2009, 10:40:05 PM »

Modified the neck raking it out 7.5degrees and cleaning up the welds

hogasm · « **Reply #3 on:** February 22, 2009, 10:42:31 PM »

Wiring outside the frame NOT

hogasm · « **Reply #4 on:** February 22, 2009, 10:45:43 PM »

Decided to internally wire everything

planenut · « **Reply #5 on:** February 22, 2009, 10:49:08 PM »

sweet keep the pics coming more

hogasm · « **Reply #6 on:** February 22, 2009, 10:49:28 PM »

Took the bike up to DCFIREMAN's house and AXIL came up to make sure DC stayed out of rare form

We installed the belt and tranny case

hogasm · « **Reply #7 on:** February 22, 2009, 10:53:19 PM »

Axil installed the crank in the cases and made sure that the endplay was perfect.

Then we bolted the case to the tranny and installed the front motor mounts. Did not tighten the bolts till the whole drivetrain was aligned

hogasm · « **Reply #8 on:** February 22, 2009, 10:57:09 PM »

When you install a larger cam into the motor it is possible that the cam lobes are too tall for the motor case and they need to be relieved.

Dan_Lockwood · « **Reply #9 on:** February 22, 2009, 10:58:15 PM »

You are going a great job on this. I love the look of the swoopy tank. The color is awesome.

Keep up the great work and more pictures please...

hogasm · « **Reply #10 on:** February 22, 2009, 11:00:00 PM »

Parts for the gear drive cams, including the new SE cam plate

yes one of the cams is missing...only from the pic

hogasm · « **Reply #11 on:** February 22, 2009, 11:03:04 PM »

You need to press the gears on the cams. If you have had the gears treated with any product, make sure that it does not keeep the cam from pressing completely into the gear

A little trick by some builders is to put a penny between the cam and the press, so the cam does not get damaged

spydglide · « **Reply #12 on:** February 22, 2009, 11:05:09 PM »

Great looking Brian. I love the nice job on the neck and the internal wiring. Clean!

spyder

hogasm · « **Reply #13 on:** February 22, 2009, 11:07:38 PM »

Work is progressing pretty well. I had to run taps into every hole and when a tap was not available, had to take a pick to remove any debris from the holes.....like powder coat

So Axil and I needed to be supervised by Mike with his cup of Dickel

hogasm · « **Reply #14 on:** February 22, 2009, 11:10:43 PM »

After pressing on the cam gears and bearings into the new SE cam plate the SE oil pump is installed and everything aligned......make sure you take a lot of time to make sure that the oil pump in aligned

hogasm · « **Reply #15 on:** February 22, 2009, 11:15:22 PM »

It was then that Mike brought Axil and I some appetizers. He was cooking up 3 racks of ribs and a couple of boston butts on the barby. I hate to admit it, but the Dickel man can cook

Oh yea back to work. Had to check the piston to cylinder wall clearance

These are Weisco pistons

hogasm · « **Reply #16 on:** February 22, 2009, 11:19:05 PM »

After making sure that the pistons will fit in the cylinders, the ring gap needed to be checked. Each manufacture has their own gap, so make sure to go by their specs. If it is too small then you will need to file the ring till the gap is correct.

The ring is installed in the cylinder at an equal distance all the way around the cylinder. See the gap in the cylinder just below 3:00

hogasm · « **Reply #17 on:** February 22, 2009, 11:22:49 PM »

Install pistons on the rods and then the rings to the piston.

Make sure that you cover the holes so that nothing can fall into the cases. It would be a bitch if one of the piston retainer clips would fall into the case

hogasm · « **Reply #18 on:** February 22, 2009, 11:26:46 PM »

"Use a ring compressor to compress the rings in the piston so that the jugs can be installed.

Make sure to install the base gasket/ or O rings before droping the jug.

This motor had the cases bored out for larger cylinders so a base gasket was used. In boring the case the o ring grove in the case was removed.

hogasm · « **Reply #19 on:** February 22, 2009, 11:30:16 PM »

T Man did the work on these heads. I sent them out to have the combustion chamber and exhaust port thermal coated.

We needed to reinstall the valves and springs in the heads.

hogasm · « **Reply #20 on:** February 22, 2009, 11:34:25 PM »

After putting the heads together we installed them along with a set of TP rocker boxes.

For some reason I forgot to take any pictures of the tranny build. As you can see it is built in this pic.

hogasm · « **Reply #21 on:** February 22, 2009, 11:38:29 PM »

This is where the weekend had to end. The motor and tranny are installed and blue tape installed on each hole to make sure on the trip hone nothing has a chance to enter into the motor.

So now it is clean up time. Every box that a part came in was chewed up by Jade, my yellow lab. So the shop needed to be cleaned, another great job for Mike

Twolanerider · « **Reply #22 on:** February 23, 2009, 12:21:54 AM »

Love the color on the frame and motor Brian. Entire project looks great. Hope you guys had as much fun as it looks like you did

.

Gettinold · « **Reply #23 on:** February 23, 2009, 06:41:47 AM »

Good luck with the rest of your build Brian. Looks like your not cutting any corners on this one.

Keep posting more pics as you finish it off.

Fired00d · « **Reply #24 on:** February 23, 2009, 06:49:40 AM »

Quote from: hogasm on February 22, 2009, 11:07:38 PM

Work is progressing pretty well. I had to run taps into every hole and when a tap was not available, had to take a pick to remove any debris from the holes.....like powder coat

So Axil and I needed to be supervised by Mike with his cup of Dickel

Brian,
Great job, thanks for sharing the play by play.

Oh, and I see "Paw Paw" got his cup of Dickel and his rocking chair.

Ride Safe,
Fired00d

FUZZNUTS · « **Reply #25 on:** February 23, 2009, 07:28:31 AM »

I like that color too, can't wait to see the finished product..............................Fuzz

naitram · « **Reply #26 on:** February 23, 2009, 09:45:08 AM »

Quote from: hogasm on February 22, 2009, 10:40:05 PM

Modified the neck raking it out 7.5degrees and cleaning up the welds

why so much extra rake?

looks like you made alot of progress

porthole · « **Reply #27 on:** February 23, 2009, 10:56:36 AM »

It looks as good as the conversations sounded

DCFIREMANN · « **Reply #28 on:** February 23, 2009, 11:41:22 AM »

Dammmmmn caught me with a small glass of Dickel!!!!!! Even worse caught me with a trash bag and ready for the clean up!

Duane you missed a good time.

Be Safe

THE DAWG

Black Diamond · « **Reply #29 on:** February 23, 2009, 11:43:16 AM »

Great info and pics. Keep em coming. Nothing like watching a scooter come to life!

JW

porthole · « **Reply #30 on:** February 23, 2009, 11:59:57 AM »

Quote from: DCFIREMANN on February 23, 2009, 11:41:22 AM

Dammmmmn caught me with a small glass of Dickel!!!!!! Even worse caught me with a trash bag and ready for the clean up!

Duane you missed a good time.

Be Safe

THE DAWG

I was working Mike, otherwise I just might have made a road trip, just to bring Jade a bone of course

hogasm · « **Reply #31 on:** February 23, 2009, 01:17:12 PM »

Quote from: Twolanerider on February 23, 2009, 12:21:54 AM

Love the color on the frame and motor Brian. Entire project looks great. Hope you guys had as much fun as it looks like you did .

Mike started a thread in pictures http://www.cvoharley.com/smf/index.php?topic=34019.0 whick explained a little about the weekend.

The color was one that I thought would look the best with chrome. It is black base with silver over. Plastic wrap was put over the silver and removed to give it the marbleized look. Then brandywine was sprayed over and then clear.

hogasm · « **Reply #32 on:** February 23, 2009, 01:22:59 PM »

Quote from: Gettinold on February 23, 2009, 06:41:47 AM

Good luck with the rest of your build Brian. Looks like your not cutting any corners on this one. Keep posting more pics as you finish it off.

Except for the painter, which screwed me, most every part was bought new but second or third hand and still in the box. That saved me a ton of money.

An example is the motor. I bought the heads, jugs. pistons rings, cams and 53mm HP Inc TB for under a grand. A lot under

A couple of things like the pistons were sent back and upgraded for $50. HP Inc installed a new shaft in the butterfly for nothing. So taking so long to get going has had it's benefits.

hogasm · « **Reply #33 on:** February 23, 2009, 01:23:53 PM »

Quote from: Fired00d on February 23, 2009, 06:49:40 AM

Brian,
Great job, thanks for sharing the play by play.

Oh, and I see "Paw Paw" got his cup of Dickel and his rocking chair.

Ride Safe,
Fired00d

And the big bottle of Dickel on the work bench

hogasm · « **Reply #34 on:** February 23, 2009, 01:28:12 PM »

Quote from: naitram on February 23, 2009, 09:45:08 AM

why so much extra rake?

looks like you made alot of progress

Neil I wanted something a little different.

Neck raked 7.5 degrees
Backbone stretched 1.5"
Rear swingarm lengthened 1" to allow for the different sprockets and still use the stock 139 tooth belt

hogasm · « **Reply #35 on:** February 23, 2009, 01:31:21 PM »

Quote from: porthole on February 23, 2009, 11:59:57 AM

I was working Mike, otherwise I just might have made a road trip, just to bring Jade a bone of course

You missed it Duane. Mikes dog Annie, a black lab, is fast as lightning. We would throw a training decoy out in the yard and let Jade get a 1/2 way lead and Annie would beat her to it. Guess Jade and her owner need to go on a diet

Talon · « **Reply #36 on:** February 23, 2009, 01:39:44 PM »

Cool, frame paint looks nice! So with the 7* extra rake, are you using the stock front end?

hogasm · « **Reply #37 on:** February 23, 2009, 01:45:03 PM »

Quote from: Talon on February 23, 2009, 01:39:44 PM

Cool, frame paint looks nice! So with the 7* extra rake, are you using the stock front end?

Using a 1' over set of springs in the front with Arnott air ride in the rear.

naitram · « **Reply #38 on:** February 23, 2009, 01:51:19 PM »

any idea how this will affect the handeling?

hogasm · « **Reply #39 on:** February 23, 2009, 02:15:42 PM »

Quote from: naitram on February 23, 2009, 01:51:19 PM

any idea how this will affect the handeling?

If you take other bikes into consideration, More rake makes a bike handle better. Too much rake is bad, and makes it want to flop over when you put the kickstand down.

One thing that I did when raking out the neck was to lengthen the backbone 1.5". This should...on paper... bring the trail back into reality...for a bagger.

One thing we noticed a few years ago when I had the opportunity to put my B&B into the wind tunnel was that with the fairing tilted back between 5-9 degrees, the bat wing fairing creates about 60% less wind drag. Too much tilt of the fairing causes the wind to catch under the fairing creating lift. Hopefully the decrease in wind drag does not create too much lift on the front end causing the front end to light and create a front end wobble.

Now to really answer your question......it is a big crap shoot

naitram · « **Reply #40 on:** February 23, 2009, 02:18:17 PM »

Quote from: hogasm on February 23, 2009, 02:15:42 PM

Now to really answer your question......it is a big crap shoot

thats what i was guessing

sadunbar · « **Reply #41 on:** February 23, 2009, 04:12:41 PM »

Quote from: hogasm on February 22, 2009, 11:10:43 PM

After pressing on the cam gears and bearings into the new SE cam plate the SE oil pump is installed and everything aligned......make sure you take a lot of time to make sure that the oil pump in aligned

Looks like you coated the gears!!

sadunbar · « **Reply #42 on:** February 23, 2009, 04:13:49 PM »

Quote from: hogasm on February 22, 2009, 11:15:22 PM

It was then that Mike brought Axil and I some appetizers. He was cooking up 3 racks of ribs and a couple of boston butts on the barby. I hate to admit it, but the Dickel man can cook

Oh yea back to work. Had to check the piston to cylinder wall clearance

These are Weisco pistons

and pistons...

sadunbar · « **Reply #43 on:** February 23, 2009, 04:15:09 PM »

Quote from: hogasm on February 22, 2009, 11:26:46 PM

"Use a ring compressor to compress the rings in the piston so that the jugs can be installed.

Make sure to install the base gasket/ or O rings before droping the jug.

This motor had the cases bored out for larger cylinders so a base gasket was used. In boring the case the o ring grove in the case was removed.

Those are beautiful cases!

hogasm · « **Reply #44 on:** February 23, 2009, 06:27:08 PM »

Quote from: sadunbar on February 23, 2009, 04:13:49 PM

and pistons...

Everything that oil touches is coated....except seals

hogasm · « **Reply #45 on:** February 23, 2009, 06:28:53 PM »

Quote from: sadunbar on February 23, 2009, 04:15:09 PM

Those are beautiful cases!

Thanks.....they were polished then chrome powder coated then clear powder coated

Trapperdog · « **Reply #46 on:** February 23, 2009, 07:51:40 PM »

Quote from: hogasm on February 23, 2009, 01:45:03 PM

Using a 1' over set of springs in the front with Arnott air ride in the rear.

One foot over springs?

It's looking great! Seems like you have really been doing your homework. Keep enlightening us with details and pics.
I miss the likes of Chief's bike rebuild posts last year so this is great.

hogasm · « **Reply #47 on:** February 23, 2009, 09:11:35 PM »

Quote from: trapperdog on February 23, 2009, 07:51:40 PM

One foot over springs? It's looking great! Seems like you have really been doing your homework. Keep enlightening us with details and pics.
I miss the likes of Chief's bike rebuild posts last year so this is great.

So give me some chit for not hitting the shift key

Now that the motor is together a small fire has been lit under my azz. Hopefully it will be together right after I get back from Daytona

AXIL · « **Reply #48 on:** February 23, 2009, 09:49:04 PM »

brian, had a good time this week end, glad to be of help. axil

Trapperdog · « **Reply #49 on:** February 23, 2009, 10:26:18 PM »

Quote from: hogasm on February 23, 2009, 09:11:35 PM

So give me some chit for not hitting the shift key

Now that the motor is together a small fire has been lit under my azz. Hopefully it will be together right after I get back from Daytona

Someone had to

Mr. We · « **Reply #50 on:** February 24, 2009, 11:09:48 AM »

Quote from: hogasm on February 23, 2009, 09:11:35 PM

So give me some chit for not hitting the shift key

Now that the motor is together a small fire has been lit under my azz. Hopefully it will be together right after I get back from Daytona

I thought you were trying to get her ready for Daytona...

Or was that the SEEG

Quote from: hogasm on February 05, 2009, 05:08:01 PM

Next day or......before Daytona

hogasm · « **Reply #51 on:** February 24, 2009, 05:30:52 PM »

Quote from: Mr. We on February 24, 2009, 11:09:48 AM

I thought you were trying to get her ready for Daytona...

Or was that the SEEG

The SEEG

I will have it ready for OBX bike week April 23-26

DCFIREMANN · « **Reply #52 on:** February 25, 2009, 11:59:52 AM »

Quote from: hogasm on February 24, 2009, 05:30:52 PM

The SEEG

I will have it ready for OBX bike week April 23-26

We shall seeeeeee!!!!!!! I hope so though.

Be Safe

THE DAWG

Author Topic: Crash the rebuild (Read 4181 times)

hogasm

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