bugger

whent to put my cyl head on last night and the damn thing won't go on. For some reason the engine is slightly back in the cradle of the frame and the head hits the tubes before the studs can go through the head!

Looks like I'm gonna have to get the engine out of the frame to build up the motor and remount the engine complete.

never mind could be worse I suppose

update:
managed to get the engine in 23/7/11, exhausts on, carbs on.

wrapping downpipes next, then the dreaded rewiring!

Nylon swingarm guide

Got myself a piece of 6mm black nylon today and made a swingarm saver. This is because of the way the bike has been raised which brings the top chain run close to the swingarm.

I cut out a cardboard template and used the exsisting 6mm bolt hole normally for the chain guard, fabricated the guide. As a "piece de resistance" I also got the heat gun out and moulded the front end around the swingarm.

Managed to lap in the valves and get them fitted.

Next I need to de-grease the head and prep for painting!

bottom end in frame

Managed to get the bottom end in the frame weekend with the help of the wife.

put on the new clutch side case and looks pretty sick!

also installed the new chain and front sprocket. The chain is going to thrash on the top of the swing arm due to the longer shocks on the back

honed the bores

Got a honing tool from a friend today and honed the bores.

what an easy job that is.

The job was quicker than picking it up in the first place.

finally got the caliper bracket back from milling and have fitted it. everything fits (just) as I can see daylight between the caliper and spokes and also between the fork mounts and disk bolts.

I'm polishing the cyl head fins ready for rebuilding/cleaning and then painting.

I'm gonna get the barrel fitted soon and put the engine in the frame. When the engine is fitted, its 'lectrics

painted barrels

prepped and painted the barrels today, still need to cut and polish up the edges which have already been pre polished.

brakes finished

Finally got my bracket more or less finished today. Not a CAD drawing in sight, all done with pencil cardboard and lots of measuring.

All that needs to be done is a 3mm milling at the caliper side, which I'll get my friend to do at work.

hit a little snag

went to do some more work on the engine and wanted to clean the oil screen filter underneath.

Damn, all but 2 screws sheared off due to tin worm, luckily the engine is out of the frame, unluckily the cover refuses to budge 1 iota.
I do have a spare cover, so I got out the slide hammer, 13mm drill and drilled a hole in the cover to accept an L shaped pull tool for the slide hammer.

 

it was a bitch to shift and i even snapped a bit of the cover off before finally bringing the recaltrient part off the engine.

Having restored bikes and cars before, I know how to get broken/sheared studding out of alloy.  I weld on nuts to the protruding screws, the heat loosens the dissimmilar metals and the welded on nut gives something the spanner can use. All the screws came out great, no problem. Took 10 mins to get them out