Topic: TAO --- The South Seattle Cafe Project

[brandEn]

Finally picked up my engine cases and a bunch of other parts from the powdercoater. I also dropped off my frame, swingarm, and guage covers. Everything looks pretty sweet and I can't wait to start installing it. I ended up powdercoating my handlebar switches and master cylinder. I was a bit worried on getting the switches put back together but it went without a hitch and they look great! After all the hours and money I have on this bike this is the first thing I am finally done with. I have about 100 semi completed tasks it seems. I am almost done with the guages but still need to put the covers on to call them done. I was planning on putting the bottom end together this weekend but I hit a snag. When I ordered my "complete" Vesrah gasket set I made the assumption that it was "complete". Well I started checking to make sure I had all the o-rings and seals to get the cases put back together and discovered I still needed a bunch. The "complete" gasket kits don't come with the oil seals. So now I am putting off the assembly until I get my countershaft seal in the mail. I managed to order and get everything else but still waithing on this one seal. Then after I managed to do all the work to hunt part numbers and such I learn that a few places offer an oil seal kit with all the parts for half of what I paid. PHUC! Oh well. Live and learn. So hopefully someone will read this and avoid this problem on their build.

Pic update soon so stay tuned...

[brandEn]

Ok new pics of my powdercoat,

Here are a few shots of my engine cases. I went with a semi gloss for these and a high gloss on everything else. I think having the high gloss on the engine sidecovers and the semi gloss on the cases will be a good combo and contrast of black. I told the powdercoater to shoot my frame with the semi gloss but I think I am going to call him and shoot it in the high gloss instead.





























Handlebar switches!




Guages almost done!


Internals ready to go in.




Now for the bad news.... When I went to remove the tappet covers from my freshly coated cam cover two of them would not budge. I had to cut one out with my Dremel! I am hoping to salvage the threads. I am not sure what went wrong but I don't think I caused it.

[tweakin]

Everything looks great, nothing like fresh powder.  That sucks about the valve cover.  Looks like maybe the tappet covers were left in when you got it ceramic coated.

[brandEn]

I am thinking I can salvage the two holes with a tap. Just drag it along the threads for some smooth cuts and straighten out the threads,

[brandEn]

Got my internals all set in place with new primary chains, cam chain, primary chain tensioner, and seals. I am waiting on a countershaft seal then I can seal them up. This task was not nearly as hard as I had made it in my mind. Actually pretty easy. Just take your time and read the manual. I don't plan on putting oil in it for a while so I coated the gears with assembly lube. I also took a few pictures of all the seals needed on the bottom end. I didn't find much info on these items in the manual so hope this helps.





Main oil gallery o-ring


This plug is just pressed in and needs an o-ring.


Front of the engine case


Two plugs on the bottom and one on the side


Neutral switch needs a new o-ring. Note that the switch is just pressed in and not threaded. Also install the o-ring in the engine case first then install the switch. It will never work trying to install the switch with the o-ring already installed on the switch.


Countershaft seal


Crank seal behind the points


one small o-ring goes under the bearing retainer next to the mount screw


If someone notices any o-rings or seals that I did not cover please let me know!

[y2kc0wb0y]

Thanks for all the details pictures! This is going to be me in a few months and I'm learning a lot.

[wohali]

Amazing work!

Like another poster, I too think I'll be going for matte black on my powdercoat, not semi/gloss, but the quality you got is great.

The red grease you used in assembly - what brand of assembly lube is that? I was just planning on going 20W50 but the red color is a nice reminder, like saying "yes, I DID lube that when putting it back in..."

[brandEn]

Hey you showed up. Thanks for the kind words! The assembly lube is Redline brand. It was like 6 bucks. The reason I used it so liberally is because my engine will not see oil for a bit yet.

[brandEn]

Finally got around to snapping some pictures of my engine and finished installing the clutch, starter, alternator and wiring.

Here is the old crusty connectors


New solder, terminals, and shrink wrap


Starter gear. Wished I would have remembered to clean the gasket surfaces before I put the case together!


Here she is with my new APE HD studs finger tight


Oh yea






The bottom end of my bottom end...


Wiring with new connectors soldered and shrink wrap installed. I also purchased a new engine wiring harness from CMSNL


Can't take credit for the wheels but I did install the rotors I drilled. Thank god I met tweakin. He lives close, has the same bike, and decided to put spokes on his bike! Thanks bro!

[going4speed]

How did you get the engine so clean? Did you take it to get cleaned at a machine shop?  Looks so awesome!!!

[brandEn]

Thanks! The engine was blasted and powdercoated. Turned out like new.

[Zaipai]

Nice project you have going. You gotta be happy with the results!

.: Scott :.

[brandEn]

Very happy with the results, and getting excited as hell to ride it!

[Stev-o]

one word: WOW!  looks great! [ok, 3 words!]

[brandEn]

one word: WOW!  looks great! [ok, 3 words!]

Thanks Stev-O. If this bike turns out they way I have planned it should be the bees knees.

[MRieck]

They bead blasted the cover and did not remove all the bead (as to why the caps were stuck). The coarse thread really holds the bead and after you screw the caps on it locks them in. It happened to me once.

[tweakin]

Looks outstanding and is bringing back some serious memories of my build.  No doubt in my mind hat you will be done by the Isle of Vashon.

[rickmoore24]

amazing work!!

[wookie]

Looks outstanding and is bringing back some serious memories of my build.  No doubt in my mind hat you will be done by the Isle of Vashon.

What's the Isle of Vashon Tige?

[tweakin]

It is a celebration of vintage motorcycles on Vashon Island that usually takes place around the middle of August.  Some years there is close to 3000 motorbikes on the island and they have a great poker run.

http://vmemc.org/IOV/IOV.htm

If you can make it next year you can crash at my place.  I live about 10 minutes from the ferry that takes you over to Vashon Island.

Looks outstanding and is bringing back some serious memories of my build.  No doubt in my mind hat you will be done by the Isle of Vashon.

What's the Isle of Vashon Tige?

[brandEn]

I officially have a roller!!! tweakin came up to help me install the engine and we got a bit more than that done!

Getting ready to install








New Kibblewhite bronze swingarm bushings

[tweakin]

Damn you got those up fast, I just got back to my place.  

The roller looks even better in person.  It will be ready in time for summer and the Isle of Vashon in August.  Thanks for the zipties and Budlight.  Hope the grease stain in the rug comes out.

[Zaipai]

Looking good man! Clearly a good days work.

.: Scott :.

[OneWheelDrive]

What an epic effort.  It's so great to see the bones of a classic restored into something beautiful that will be around for another hundred years!

[going4speed]

Looks phenomenal and makes me think my project will take another year.   

What wheels are those and can I have them?