Author Topic: Total Rebuild Thread (Read 22624 times)

bunghole · « **Reply #100 on:** July 18, 2008, 03:38:19 PM »

Quote from: martino1972 on July 18, 2008, 03:21:50 PM

you should post a picture of yourself here,i keep picturing you looking like your aviator.....

Deedle neer neer neer neer neer neer neee!

Thanks scartail!

I checked the valve to guide clearance and it was a bit sloppy, so I ordered a new set of guides from dynoman. He is great to do business with and very quick. He got the UPS out same day.

I suppose I'll be bringing the head to a shop to put the new guides in. Unless you all think I can do it with a hammer

Do I need to recut the seats? I'm installing new stainless valves from Dynoman as well.

bunghole · « **Reply #101 on:** August 05, 2008, 03:48:22 PM »

I haven't updated in a while, so I thought I'd get this thread up to date:

Not much has progressed as I've been busy with other things. I did have new valve guides installed. I put the cases back together and was really proud of my work and then realized that I didn't install the con rods on the crankshaft, so I had to resplit the cases and clean off all the Three Bond. Tonight, I plan on getting that taken care of and maybe even installing the pistons and cylinders.

Couple of questions:

1. Are all of the oil seals installed AFTER the cases are back together?
2. Does anyone have any suggestions on the easiest way to compress the rings while sliding the cylinder down over them? Since you have to do two at a time, I was thinking it might be tricky.
3. Loctite on the heavy duty APE studs? I've heard some people (MRieck I think) say they use it and others recommend oiling the threads so that the torque readings are accurate.

Thanks!

bunghole · « **Reply #102 on:** November 02, 2008, 05:52:03 PM »

Wow!

Three months since I updated this thing. It seems like I've been running in place on this rebuild. Lots of working with little progress. Lots of getting sidetracked on silly details. Lots of life outside of the garage.

I've really made significant progress over the last couple of days, so I thought I'd update this thread and maybe get it rolling again.

Finally got the engine buttoned up. I spent countless hours polishing/buffing the covers. Here is the finished product:

Specs on finished engine:

836 Wisecos
Stainless valves from Dynoman
Heavy duty valve springs
Titanium retainers

I guess we'll find out if I screwed something up when I try to start it the first time.

RC Cam

bunghole · « **Reply #103 on:** November 02, 2008, 06:05:22 PM »

With the engine done, it was time to start making some progress on the frame. I wanted to remove all extraneous bits that I wouldn't be using, so I removed the left side passenger peg mount. I kept the right side as a mount point for the exhaust. I removed the airbox mount points as I'll be using pods. I also removed the seat lock, helmet hanger and some of the chain guard mounting tabs.

I also wanted to relocate the ignition and choke since the stock '77 has them up near the gauges and I want to clean that area up. I wasn't sure where to mount them and was concerned about them interfering with or being interfered by other components. Unfortunately, the only way to make sure that didn't happen was to get the engine into the frame and do a mini mock-up.

I mentioned earlier in the thread that there is no way my back is going to cooperate with moving that engine, so I stole an idea from another member on the board and fabricated a sling contraption to allow me to install the engine without using any of my puny muscles.

Here are some pics:

Worked like a charm! I can't recommend this enough. Took me about 3 hours to put the whole assembly together using some galvanized pipe, 3/8" (I think) bar, some eye bolts and webbing strap. Once completed, I was able to install the engine in about 20 minutes without much effort (I think once I get the hang of it, I'll be able to get that time down significantly). Removal was done in a matter of a few minutes.

So I was able to determine a good spot for the ignition and choke...left hand side right between the tank and seat. I fabbed up a mounting plate and welded it in:

Here is a wide shot showing a bit of the bike starting to take shape:

bunghole · « **Reply #104 on:** November 02, 2008, 06:08:44 PM »

I just looked at those last pics and man do arc welders do a messy job. Nothing a angle grinding and paint won't remedy.

By the way, the choke cable I used is for Harley Sportsters. It is the perfect length for the new mounting point.

JAG · « **Reply #105 on:** November 03, 2008, 12:27:15 PM »

Glad to see ya back at it! I like the idea with your ignition..

Are those spitfires in the back ground I see?? I looked everywhere to find the raised white lettering style for the rear tire and I couldn't find it. Where were you able to pick those up? And what size are they?

Keep it moving along BungHole!!!

bunghole · « **Reply #106 on:** November 03, 2008, 12:42:17 PM »

Hey Jag. I got the Spitfires at Dennis Kirk...

Rear:

http://www.denniskirk.com/jsp/product_catalog/Product.jsp;jsessionid=HZGCX5TMOJV43LA0WTISM4VMDK0OWIV0?store=Main&skuId=65697

Front:

http://www.denniskirk.com/jsp/product_catalog/Product.jsp;jsessionid=HZGCX5TMOJV43LA0WTISM4VMDK0OWIV0?store=Main&skuId=65688

David · « **Reply #107 on:** November 03, 2008, 01:27:52 PM »

The rebuild is looking great!

A while back, you asked for info on what to order for mounting bolts. Did you ever receive any info? I am also doing a rebuild and am missing some mounting bolts. Would like to order some, but not sure what to order.

bunghole · « **Reply #108 on:** November 03, 2008, 01:47:26 PM »

Quote from: David on November 03, 2008, 01:27:52 PM

The rebuild is looking great!

A while back, you asked for info on what to order for mounting bolts. Did you ever receive any info? I am also doing a rebuild and am missing some mounting bolts. Would like to order some, but not sure what to order.

I just posted another thread asking the same question:

http://forums.sohc4.net/index.php?topic=42711.msg442824#msg442824

If I find any sources or solutions, I'll be sure to post it here.

martino1972 · « **Reply #109 on:** November 03, 2008, 03:59:52 PM »

Quote from: bunghole on November 02, 2008, 06:08:44 PM

I just looked at those last pics and man do arc welders do a messy job. Nothing a angle grinding and paint won't remedy.

By the way, the choke cable I used is for Harley Sportsters. It is the perfect length for the new mounting point.

yeah,to get a nice job there,you will have to use a mig or tig welder..
it can be done with a arc welder,but you will have to be really good at it...

ksmith0034 · « **Reply #110 on:** November 14, 2008, 12:43:28 PM »

Lookin good! One tip that would have saved you a TON of work when putting the engine back in the frame: lay the engine on its right side and carefully lower the frame down over it. I did mine that way and I can actually say that it was EASY - took about 5 minutes. I wish I could have told you that sooner! You can see a couple pictures on my build site at www.stocker2rocker.com

odin836 · « **Reply #111 on:** January 30, 2009, 01:38:09 AM »

Bunghole - Hows the bike going?
I like the detail in your photos and descriptions.

Gives me hope...

bunghole · « **Reply #112 on:** January 30, 2009, 10:00:55 AM »

I'm getting there slow but sure!

I've got the engine in the frame, mounting hardware fabbed up for the tail section, rear swingarm and shocks installed.

I'm now working on the front end and plan on having a rolling chassis before continuing with the body work.

I'll try to get some pics of progress up this weekend.

Thanks for the encouragement!

JAG · « **Reply #113 on:** February 02, 2009, 04:49:21 PM »

Keep it going Bud!! Can't wait to see those pics..

It'll be nice to have it all good and ready for the spring

JAG

martino1972 · « **Reply #114 on:** March 22, 2009, 10:25:05 PM »

any progress.......

bunghole · « **Reply #115 on:** March 23, 2009, 09:18:53 AM »

Martino...

You dig up my old thread and make me feel guilty for passing a year without completing this thing

I've got the front end installed, engine in frame.

When I went to put the nice, powdercoated rear wheel on, I discovered I had lost the sprocket carrier. Looked for hours and hours and can't find it. It was powdercoated as well. Pissed me off!

So I found a new one on Ebay and I will have to ship that to Woodys for powdercoating once I get it and clean it up. I think it has a bearing in it, so I will have to find a replacement on that as well.

I started toying around with the gauge cluster last night, as well as repainting and refurbing all of the bar controls.

It's getting there....really slowly....but getting there.

I'll try to remember to post some pics.

JAG · « **Reply #116 on:** March 24, 2009, 08:34:03 PM »

Yes, definitely would love to see those pictures..

How are you thinking you are going to mount the seat?? I assume a couple of bolts through the frame, but I was curious as to where exactly..

JAG

FunJimmy · « **Reply #117 on:** March 25, 2009, 12:55:49 AM »

Beautifully meticulous.
What a great example of build quality.

Touché.
FJ

bunghole · « **Reply #118 on:** March 26, 2009, 07:05:04 PM »

OK...pictures as promised...

Hush · « **Reply #119 on:** March 26, 2009, 07:09:34 PM »

Lookin nice Bungee, but that's what happend when you have too many toys....not enough time to play with them all.

scartail · « **Reply #120 on:** March 27, 2009, 08:32:05 PM »

That is one really nice project you got there. What color scheme are you going for?

bunghole · « **Reply #121 on:** March 27, 2009, 10:57:24 PM »

Thanks folks.

Color scheme is a dark hunter Rustoleum green. I'll accent with a vintage Honda wings logo on the tank and an 836 logo on the sidecovers. Decals were made by lordmoonpie and he did a beautiful job. I just hope I can do them justice and apply without goofing the whole thing up.

I'll need crossed fingers from ALL members when I fire it up for the first time. It was my first ever engine rebuild of any type and I'm not sure it will even kick over. We'll see. Heck, the rebuilt engine has been sitting for at least six months without any movement. For all I know, it is rusted solid in there

bunghole · « **Reply #122 on:** March 27, 2009, 11:02:19 PM »

Quote from: Hush on March 26, 2009, 07:09:34 PM

Lookin nice Bungee, but that's what happend when you have too many toys....not enough time to play with them all.

No doubt!

I need to get some of these motors running to at least keep the oil circulating. I haven't ridden the Suzi in so long that I have to pull the carb and clean the gunk out. Shameful!

Hush · « **Reply #123 on:** March 28, 2009, 02:26:30 AM »

That bike has take me out and thrash me written all over it

hapakev · « **Reply #124 on:** March 28, 2009, 10:25:33 AM »

I really dislike the shape of that tank, but I must say you made it beautiful with those knee dents. You have an amazing build going here, cant wait for the finished product pictures.

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Author Topic: Total Rebuild Thread (Read 22624 times)