Topic: '75 572 for the Tinman - Powder Coating done

[calj737]

A very good pal of mine who rides, is stuck with Harleys for his road bikes. Tried to talk him into converting his KTM 525 into a street bike, urban brat, but couldn't do it. He's pretty interested in the 550 thread I've got, so, he's put me to task to make something for him.

He wants something fun, dark, nefarious, and vintage soul. Hmmmm... Gave me a decent budget to work with as he wants good quality stuff on a bike he plans to keep a while. Since he's my age, no clip-ons, and no USD forks.

Happened onto a project gone "south" locally, and picked up this donor. Motor does rotate, carbs are in tough shape, and aside from the passenger brackets and seat brace being chopped, frame is in otherwise decent condition. Fork uppers are toast, and the important stuff seems okay to rebuild from.

Hoping this project will go pretty quickly, as most of it is somewhat similar to my other two, with some small changes. Sources for goods and vendors are already identified, so way ahead in those areas. CognitoMoto will be getting some pretty hefty PP checks, and hopefully can get on Mike's schedule for some head work.

Will be using the Wiseco 61 pistons, got a 650 cam from Goldarrow, and still deciding between stock carbs or a setup that Devin turned me onto with 2:1 Mikunis. He says he recently got a setup for his bike, and initial reactions is he loves them. I like the idea of 2 carbs, and the Mikunis are a top-rate product. I'll do a bit more investigation with Devin before deciding.

So, here's evening of pickup:













Here's the "save to reuse" pile:




Once I get this thing torn down, blasted and coated, I'll post up some progress pictures. But this will give you an idea of what I have in mind:

[riverfever]

Another project??!! I know it's not yours but you are a busy bee. I'm intrigued. As usual. 

[goldarrow]

Nice to have a project with good turning motor surface looks rough, paint or polish???

[Trad]

In for this one Cal. Looking forward to seeing the progress.

[SOHC4 Cafe Racer Fan]

Subscribed and interested, Cal. 

No USD but will you be using the stock triple or something else? 

[calj737]

The engine will be fully torn down and powder coated: wrinkle black for the cases, satin black for the covers.

Triple tree will be the Joker I'm using on my 550, but in black. Gotta press the stem back .780 for proper fitment. Probably use Racetech Gold valves in the forks instead, plus add a Tarozzi brace. Should make this thing handle really well without the bulk of USDs.

Of course, all the electronics will be MotoG, so we've got that whole system covered too. Don, I think I'm going to take your lead and order a Lossa 4:1 this time. Timing and availability is important for me, and it doesn't appear Chris has any inventory for a while. Pus, I can use the extra few hundred bucks to pay for some other bling. It will of course be ceramic coated inside and out.

[Stev-o]

Rough looking start point, will be an amazing transformation. Subscribed.

[calj737]

Where's the fun in fixing up a decent bike? Isn't it all about transforming forgotten old bones into a new lease on life motorbike? Besides, if I whacked and hacked up a good survivor, I'd never forgive myself (and I'm sure some around these parts would run me off).

[mazen0822]

 and still deciding between stock carbs or a setup that Devin turned me onto with 2:1 Mikunis. He says he recently got a setup for his bike, and initial reactions is he loves them. I like the idea of 2 carbs, and the Mikunis are a top-rate product. I'll do a bit more investigation with Devin before deciding.

Can you speak more about this?

[calj737]

I'd refer you to Devin for better details. I can say this: it uses an intake manifold pairing cylinder 1/2 to a single Mikuni 34 carb, then same for 3/4. Devin speaks highly about his impressions with the setup and they run about $600, which is pretty dang cheap in my eyes.

You can reach Devin via member cognitomoto or sales@cognitomoto.com

[calj737]

Well, nothing like mild temps in the Mid-Atlantic to get you interested in tearing into a greasy, sweaty mess. Plus, the Mrs and 2 little ones are away on holidays, coming back Tuesday PM. Time to make hay!

Gotta get the motor torn down to get the trans out so it can be sent out to be undercut on 2-5 (thanks, Brent!). Fortunately, motor turns over freely, and I've got my technique down for pulling JIS screws ;^)




Plugs 1-4 in sequence. #4 has my eye, but since a full over-bore and Stage 2 job is coming, not really concerned.


Here's a first for my projects; a spotlessly clean rotor 


Birds nest or mice, can't tell...


There's a $100 saved!


Must not have seen much use before being abandoned


#1 Left to right. Rockers seem decent, but lobes are grungy 



#3/#4


Bidding starts soon for this little beauty 


I'll see if I can remove the rust and leave the chrome. But it will sell too if it cleans up



TEC timing plate. Going to market with this too-



Grungy but undamaged



A glimpse of this gave me shudders!




Hardweld here I come!


#1 lobe


Pretty clean top end


1 Hour later, the pile looks like this:


Head didn't want to come along, so it brought a friend with it 


I'll have these cleaned up an mic'ed. If they're still in good shape, I'll treat them with DFL and Cermet and sell them to a member as stock replacements.



Things really going my way- lifted off in a single piece!


Needs new clutch plates, discs and springs, but otherwise pretty sparkly underneath


All told, about 3 hours of to get it torn down to there by disassembling carefully. Even the stock valve cover seal is in great condition. Captured the oil, and for curiosity I'll go thru it with a magnet but not expecting to find much. I'll have the shop split the cases, run it thru the parts washer, and I'll take the cases and trans. Order up a new primary and cam chain, tensioner on this one is really good.

Need to drop the jugs and head to coated, then off to machining. I sure hope Mike R got some rest, because here comes another head to pay his holiday bills!

[SOHC4 Cafe Racer Fan]

That was a quick and clean tear-down.  Despite the grunge on the outside, the inside looks like the motor had very low miles. 

[calj737]

Some parts. The head gasket and base gasket showed no signs of leaks. Really, none of the case seams were leaking. The underside and rear is a mess, that's easily attributed to not being cleaned, and then abandoned.

The cam wear is most intriguing though. Pretty bad wear across the faces of #1 lobe, and a few others show distinct signs of wear, but not the rockers. Oh well-

[Stev-o]

You made quick work of that. 

[Trad]

Nice work Cal; Looked like a breeze compared to most. Fingers crossed everything else goes that smoothly.

[Tinmanman]

Cal,  Your buddy is a lucky Guy to be getting a CalCustom.  Why ride anything else ? can't wait to see it progress

[calj737]

Kind of you to say, I'm sure he will like it as I've spent a great deal of time picking his brain. Now, to execute it 

[calj737]

While I await the cases to be powder coated, and some parts to arrive, going to get to work building the new swing arm. Why build a new swing arm to handle dual shocks you ask when the stock unit works well?

Because I'm lazy and don't want to brace the stock unit, and because I want open the width enough to allow a wider tire, and why build a custom bike and leave stuff stock? I know, these aren't compelling reasons, but, if you've got billet tubing, what else you gonna do while you wait? Besides, this bike is for a very good mate of mine, and I want to build him the best bike I can, custom touches wherever possible, for his money.

New material for the swing arm:


This should be stout enough:



New material I will use to mill axle holders from. Again, billet 6061 drops that I got for free!


I'll get in to the shop next week and start laying out the templates, mill the axle ends, and being bending and cutting the tubing. Also bought 1/2"x5" flat stock for some bracing at the pivot. Then, I have to bore the tubing for the pivot rod and bearing. And of course, TIG 'er up!

[Retro Rocket]

Logged in for swingarm making...

[Stev-o]

Logged in for swingarm making...

+1.   Looking forward to the write up.

[Tews19]

Cool swing arm! I'm in !

[SOHC4 Cafe Racer Fan]

Sweet stout swinger! That's some serious tube!

[calj737]

0.375 versus stock 0.063. Rule of thumb is twice the wall thickness when using aluminum versus steel. (I think I got it covered  ).

I had thought about using solid rod for the longest time. Then, whilst at the metal supplier inquiring about material and lead time for some goodies, bumped into and chatted it up with one the "managers". He was pretty intrigued by what I was buying and building at the time. It was then that he gave me a great reference that persuaded me not to use rod, but instead tubing. Always reminds me to remember that for all the stuff I know, I still don't know jack!

Essentially, the tubing with 3/8 wall is about 3x stronger that  a solid rod of equal OD. Go figure... And (I couldn't confirm the stock material from original swing arm) I'm speculating based upon some similar examples, this tubing should be about 4-5x stronger than stock. Hence, no secondary brace "anticipated".

[bwaller]

Yep the tubing will be far stronger than solid. I remember straightening a stock arm in the vice with a 5' piece of pipe. I always remembered that wondering how they didn't flex while riding. But with the axle tight they don't...or don't enough to ever notice.

[flatlander]

Will be using the Wiseco 61 pistons,

could you tell me more about these? on the wiseco site they list them for the 550 up to 59mm only but maybe you use something else?