Topic: Sandcast #97 restoration

[Justin]

Upon closer examination, it helps but doesn't get me all the way there. The drawing isn't quite accurate in the way it depicts the triangles, but there are slight bends in each tube and I don't have the measurement between sides to show the clearance for swingarm. I may have a k3 in storage and I'll have to check those triangles...

[SoyBoySigh]

BUMP

This thread is a beautiful surgical/anatomical dissection of the Honda piece de resistance - simply a marvel the level of detail.

There's only one way this could be improved:

To have been a fly on the wall, back in the original factory - follow the most beautiful women who worked there as they assemble the bike, wearing tight skirts & their hair up in a bee-hive. Of course it would all have to be photographed in luscious vintage Kodak film....

There's a good film like that, about the Suzuki RE-5 - Y'all know the one? Well - is there anything like that about the Honda factory?

-S.

[SoyBoySigh]

Spooky - must be that Google is reading my thoughts, via reading what I type on this site. Yeah, spooky.

I poked into YouTube to check into the classic Honda factory films, and hadn't even punched word one into the search bar - THIS was waiting for me upon opening the page, a suggestion that I might enjoy - perhaps you'll enjoy it too:

[markb]

Interesting, thanks.

I finally got around to replacing the seal in my cam chain adjuster and installed it on the engine.  There are differences between the early sandcast and later holders.  In the first two pictures my original sandcast holder is on the left.  This view shows where the holder is spot-faced for the mounting screws.


The original one is also much rougher than the later one as shown here.


Here’s close up showing the rougher sandcast finish on the original.

[markb]

Here’s my rebuilt Tokico 1 caliper.  They were used on the early sandcasts. 


Here’s a close up of the name.


Here’s a shot of the back side.


Note the knurled head screws and the long center rib (which extends down close to the pin on the brake pad) which are both characteristics of the early caliper.

[markb]

I also got my final drive flange assembly done.


It has the early 45 tooth sprocket.


Here’s a shot of the back side.


The early sandcasts have “8” head bolts for fastening the sprocket.

[MoMo]

Good work as always Mark...  Do you have an estimated time of completion?....Larry

[SOHC4 Cafe Racer Fan]

Mark,

Crazy attention to detail.  Question: are you going 100% accurate on the restoration? As in ball bearings in the steering head, too?

[markb]

Good work as always Mark...  Do you have an estimated time of completion?....Larry

Thanks.  I'm hoping to have it put together by this fall so I can at least run it.  It may not be completely correct but I can clean up some details over the winter.

Mark,

Crazy attention to detail.  Question: are you going 100% accurate on the restoration? As in ball bearings in the steering head, too?

I am going for as accurate as possible and yes the balls in the steering head are exactly like original.

[markb]

Here’s a shot of my oil lines before working on them.  I would like be able save them since they are the original rubber lines.  Whether or not they will leak is yet to be seen.


Here is after working on them.  I flushed them out good and dragged a wire through with a bit of cloth on it.  That was a little tricky with the corners but internally I think they’re pretty clean.  Then I cleaned them up on the outside.  I wire brushed the aluminum and then used aluminum brightener.  I used Rubber Renew on the rubber and they cleaned up nice and got back some flexibility.  Then I sanded and painted the steel parts.  I think they look great.


I tried quite a few paints with no luck.  The Eastwood’s Clear Zinc didn’t even look close.  It came out a matte grey.  Then I stumbled across a can of this laying around in our shop and tried it.  I never would have guessed it would look so good.


It almost seemed too shiny but compared to some of my brighter zinc plate parts it is almost an exact match.  I’m happy.

[Stev-o]

It's all in the details, Mark. And you nailed it. 

[markb]

Just to avoid confusion, the Bright Coat Metallic Finish comes in 3 colors: aluminum, gold and chrome.  The color I used was chrome.  The can just has the wrong cap on it.

[Old Scrambler]

Good stuff, Mark................Aluminum Brightener; Bright-Metal (chrome); will be added to my shelf

[Restoration Fan]

This thread is just loaded with awesomeness!
Mark,
Thank you for sharing this special piece of history with us. 

Ron

[markb]

I haven’t posted for a while and unfortunately I’m way behind on my posts.  But I have a good explanation.  I was hoping that I would have assembly mostly completed by fall so I could start and ride it for a bit before putting it away and working on some final details over the winter. 

So then I was contacted by the Petersen Automotive Museum in Los Angeles.  They have been closed for renovation for a while and will be reopening December 6.  They are going to have an exhibition of 18 different bikes on display and asked me if I would loan them #97. Of course I was flattered but the thought of not having the bike around was a bit unnerving.  However, it didn’t take me long to change my mind.  It’s not every day that one gets an opportunity like this.

After that I spent just about every spare minute working on it and as a result I did finish the assembly.  I actually may not have without the extra pressure.  I did run out of time to fire it up but decided that wasn’t a bad thing because then I won’t have to worry about gas in the tank and carbs.  I was also hoping to get some really decent pics before it got picked up.  That will have to wait too. 

So here is the (temporarily) finished project.


I just hope it’s up to the standard that the museum expects.


They sent an awfully big truck to pick it up.


It is a little scary seeing it being loaded up to be hauled away.


Fortunately they definitely know what they’re doing.


One thing I have learned is it’s not as much fun when there is a deadline but I am very happy I got it is far as I did and now I’m ready for a little break from it.  I aleady have a short list of things I want to do when she comes back that I’ll post later. 

So now that the pressure is off I will take some time to post some of the pics I took over the summer.  And it’s not like I don’t have anything else to keep me busy.  I have #576 that I would like to have finished by spring.  We’ll see how that goes.    And of course I’m planning on going out to visit #97 maybe in January or February. 

[CycleRanger]

I just hope it’s up to the standard that the museum expects.

I think you've got that more than covered!   

I just hope you got LOTS of pix of the paint, chrome, cases, etc. in case there's any damage.
I also hope you signed an agreement that covers damage, full replacement cost, etc.

That being said, it is extremely cool and fitting your bike should be displayed in a museum!
Maybe it should go on tour. 

[Greggo]

Did they invite you to the big opening gala?  I'm glad that guy from Petersen convinced you...probably not a better example out there!

[SOHC4 Cafe Racer Fan]

I'm planning to check out the re-opened Peterson next month.  I'll look for your bike!

[MoMo]

Congratulations Mark, quite an honor and well-deserved...Larry

[750K]

Beautiful looking bike, can't wait to see proper pics once you get around to it. Amazing job and attention to detail!

[calj737]

The question isn't, "Is your bike up to their level", but "are theirs up to yours"! 

[markb]

Thanks for all the nice comments. 

I also hope you signed an agreement that covers damage, full replacement cost, etc.

I did.  There is always a risk that something will happen but I'm more than covered on the insurance.  Hopefully I'll never need it.

Did they invite you to the big opening gala?

I can't make it down there when they reopen but they did say they would send me free tickets when I go there.  I'm looking forward to that.

I'm planning to check out the re-opened Peterson next month.  I'll look for your bike!

I'll be anxious to hear what you think.

[Old Scrambler]

I'm with Calj on YOUR standards............GREAT JOB

[markb]

Besides starting it and riding it I still have a few things I'd like to do on #97.  Hopefully some of you may get a chance to check it out.  If you do please let me know if there is something that looks incorrect.  I was going to see if anyone would catch a couple of details but I decide to point them out.

I used a new wiring harness for now.  I have several that I am going to try to refurbish over the winter.  Also I still need to redo the oil pressure switch wire.  Those aren’t details you would see.  If you look close you may see the following items.

I think the carbs are bit too dark.  I would like to find a way to lighten them.

I used some repro tach and speed cables that I had made up from MotionPro.  They’re not bad.  They have almost correct looking short nuts but I am going to try to get some closer matches.

The fuel lines are the wrong size.  I just ran out of time to source the right ones.

And the spoke nipples are incorrect.  I didn’t lace up the wheels.  I was more worried about the color being correct and didn’t notice that I had given the mechanic the wrong ones.  Here’s a pic showing the correct nipples on the right.


When I get time I will make a list of everything that is correct.

[Don R]

 I missed the spoke nipples on the rolled rear rim of my #5511 too. I have them labeled in a container with other sandcast bike parts. If I ever swap out the tire, I'll get it right then.