Author Topic: Sandcast #97 restoration (Read 216844 times)

MCRider · « **Reply #800 on:** December 31, 2018, 09:40:24 AM »

Righto.

AS to order, I tighten the 6mm down first to gently pull the head down against the friction of the dowels, stop at hand tight. Then yes, they will be loose again after the nuts, and will need to be hand tightened again.

The comment about order of removing, is VERY important. 6mm bolts first, then the nuts. Otherwise the 6mm will become so tight as to be often mangled or even broken off when removing.

One time I removed the nuts first and had to put them back on to get the 6mm out.

markb · « **Reply #801 on:** January 01, 2019, 06:21:20 AM »

I pulled the head and cylinders off and installed Heli-coils. I thought about doing the one in place but decided against it because of the accuracy and the chips. I looked at all of the 6mm holes and at least one more of them looked suspect so I did all four under the pucks.

They were pretty close to the sleeve flanges but the tap just barely went into the flange.

While I was at it I did the rear one too. I don't want to pull it apart again.

MauiK3 · « **Reply #802 on:** January 01, 2019, 07:52:36 AM »

That looks like it should hold up fine. Those fasteners likely help the gasket to stay in place and not creep over time from heat movement.

markb · « **Reply #803 on:** January 01, 2019, 11:46:42 AM »

Finally, the cylinder and head assembled. The original cylinder and head. The 6mm screws torqued down just fine. I’m happy I went that route in spite of the extra work.

Here’s a shot where you can see the two small o-rings under the towers instead of four on later heads. I did that to document that the original head was in fact installed.

MauiK3 · « **Reply #804 on:** January 02, 2019, 10:32:25 AM »

Steve-O said I should do another bike.
I resist because of the other projects I have going, not bike related.
Seeing your #97, however, makes this hard to resist. I look through craigslist and cycletrader and see various CB750's, some very expensive and already done and some horribly molested at high prices. I guess if I ever saw one that looked right I'd have to consider it.
Yikes, this thread is dangerous!!
Keep up the good work, it's great fun reading it.

markb · « **Reply #805 on:** January 03, 2019, 09:04:37 AM »

Well, things were going good. I got the camshaft holders and cam installed and when I torqued the 56mm screws for the caps three out of four of them stripped out.

It’s the holes with the pins (circled in red).

So the head is back off. Three steps forward, two steps back. These are going to be a little bit trickier because of the counter bore for the pin. Fortunately the O.D. of the Heli-coil is smaller than the 8mm pin hole. Not much choice as to what kind of insert to use here.

Some of you may be thinking that I’m maybe just over torqueing the screws. They weren’t even close when they let go. To make sure I checked my torque wrench again and it is right on. This is the first time assembling this cylinder and head since they came apart. And you probably recall that they came apart hard. I’m guessing the threads were damaged then. The other thing is that the 56mm screws could be a little longer. In fact on later K0s the screw is a 60mm. If you subtract the washer and the thickness of the holder and cap and the 8mm depth of the pin hole and actual length of the screw you’re lucky to have 8mm of thread engagement. With a 60mm screw in would be 12mm engagement which would be a significant improvement.

I’m also going to be checking all of the tapped holes for the valve cover before I put the head back on.

markb · « **Reply #806 on:** January 06, 2019, 02:54:53 PM »

I’m almost ready to put the engine back in the frame.

I Heli-coiled the holes with the pins under the cam holders. As long as I had to do it I did all four. Then I assembled the cam towers before mounting the head to make sure everything else would torque down. I also checked the valve cover. I’m glad I did. I had three of the 63mm pan head screws that were about 0.5mm from tightening, even with the gasket. Almost didn’t notice it. I thought they were tight but they were bottoming out in the tapped holes. I thought about just regrinding the screws down for those holes but if and when it comes apart again it might not be noticed. Just the kind of stuff that previous owners do to mess us up. I was able to run a tap in those holes and get just enough thread. I checked the cam chain tensioner too. I stripped out a hole for that years ago (and I Heli-coiled it). The early parts book calls out a 36mm screw and later it was changed to 40mm. I checked and there wasn’t much of the screw sticking out with the 36mm. The tapped holes were just deep enough to use the 40mm screws. So I decided it was better to be safe than correct.

I got my rubber inserts for the fins. Just started putting them in when I ran out of gas. They go in pretty tight. The last thing I want to chance is cracking a fin. I think I’m going to trying heating them or boiling them in water to soften them up a bit.

Tews19 · « **Reply #807 on:** January 06, 2019, 07:16:54 PM »

Wow, you are moving fast now that you are back at it! Shoot, How much do you charge to assemble a K0 engine!??

markb · « **Reply #808 on:** January 07, 2019, 05:42:21 AM »

Basically putting top end together three times in a week does make it go a little faster. To answer your question, it depends on how much rework.

I couldn't have afforded this job if I had to pay someone to do it.

MauiK3 · « **Reply #809 on:** January 07, 2019, 09:09:04 AM »

Looking great, this one is worth the work.

MauiK3 · « **Reply #810 on:** January 20, 2019, 09:28:18 AM »

How is #97?

markb · « **Reply #811 on:** January 27, 2019, 09:32:18 AM »

Really good. As of yesterday she is finally together again. Once I got the engine together things went pretty good. So now in addition to the original cases it has the original cylinders and head along with the original valve cover.

I also found that the front brake was sticking so I had to pull the caliper apart and while I was at it I cleaned up the master cylinder and flushed the rest of the system. It had sat for quite a while. Works good now.

Here’s some pics of my setup for installing the engine.

Of course it helps to have a nice hoist.

Start to finish about 45 minutes and no nicks.

And I forgot to mention I now have the correct spoke nipples installed. I have a few more details to correct but she’s getting close to being as correct as humanly possible.

MauiK3 · « **Reply #812 on:** January 27, 2019, 09:37:16 AM »

Beautiful
So it is now like a Vic World sandcast, maybe better. What a great example. It needs to be preserved somewhere.

If I may pry, what is the shop you are in used for? It's so clean!!!!

MoMo · « **Reply #813 on:** January 27, 2019, 01:42:28 PM »

Quote from: MauiK3 on January 27, 2019, 09:37:16 AM

Beautiful
So it is now like a Vic World sandcast, maybe better. What a great example. It needs to be preserved somewhere.

If I may pry, what is the shop you are in used for? It's so clean!!!!

and quite large to boot, envious

fastbroshi · « **Reply #814 on:** January 27, 2019, 05:04:21 PM »

Quote from: markb on January 27, 2019, 09:32:18 AM

And I forgot to mention I now have the correct spoke nipples installed. I have a few more details to correct but she’s getting close to being as correct as humanly possible.

What's so special about these spoke nipples?

markb · « **Reply #815 on:** January 28, 2019, 06:22:53 AM »

Quote from: MauiK3 on January 27, 2019, 09:37:16 AM

Beautiful
So it is now like a Vic World sandcast, maybe better. What a great example. It needs to be preserved somewhere.

If I may pry, what is the shop you are in used for? It's so clean!!!!

Thanks for the compliments.

It's my company's shop. I have a little area where I work on my bikes. It's a bonus to have all the other resources available.

markb · « **Reply #816 on:** January 28, 2019, 06:23:50 AM »

Quote from: fastbroshi on January 27, 2019, 05:04:21 PM

What's so special about these spoke nipples?

The correct nipple is on the right. See how it’s turned down on the end.

markb · « **Reply #817 on:** February 03, 2019, 09:07:25 AM »

I took some time this weekend to go the Minneapolis Motorcycle Show.

The local chapter of the Antique Motorcycle Club of America asked me to bring 97 to display.

That’s why I needed to get it back together.

I answered a lot of questions. It’s amazing how many people have at least heard of a sandcast.

MoMo · « **Reply #818 on:** February 03, 2019, 12:28:03 PM »

Exquisite, the bike that is...Larry

MauiK3 · « **Reply #819 on:** February 03, 2019, 02:45:29 PM »

You braved the Artic conditions? That’s dedication!
I would love to have been there

SOHC4 Cafe Racer Fan · « **Reply #820 on:** February 03, 2019, 08:50:47 PM »

Nice. My buddy Brady Walker has been putting together the AHRMA displays at the IMS shows.

Bankerdanny · « **Reply #821 on:** February 06, 2019, 09:52:18 AM »

Quote from: markb on February 03, 2019, 09:07:25 AM

I took some time this weekend to go the Minneapolis Motorcycle Show.

I answered a lot of questions. It’s amazing how many people have at least heard of a sandcast.

Cool. The Chicago show is this weekend, I am looking forward to it. Unfortunately I will have to drive. Back in 2008 or so it was in the low 60's and I was actually able to ride my FJ1200 and MC parking was free.

Tews19 · « **Reply #822 on:** February 07, 2019, 07:55:39 PM »

Quote from: Bankerdanny on February 06, 2019, 09:52:18 AM

Quote from: markb on February 03, 2019, 09:07:25 AM
I took some time this weekend to go the Minneapolis Motorcycle Show.

I answered a lot of questions. It’s amazing how many people have at least heard of a sandcast.

Cool. The Chicago show is this weekend, I am looking forward to it. Unfortunately I will have to drive. Back in 2008 or so it was in the low 60's and I was actually able to ride my FJ1200 and MC parking was free.

Danny, any info about this event? Is it saturday and sunday?

Bankerdanny · « **Reply #823 on:** February 07, 2019, 08:00:23 PM »

Quote from: Tews19 on February 07, 2019, 07:55:39 PM

Quote from: Bankerdanny on February 06, 2019, 09:52:18 AM
Quote from: markb on February 03, 2019, 09:07:25 AM
I took some time this weekend to go the Minneapolis Motorcycle Show.

I answered a lot of questions. It’s amazing how many people have at least heard of a sandcast.

Cool. The Chicago show is this weekend, I am looking forward to it. Unfortunately I will have to drive. Back in 2008 or so it was in the low 60's and I was actually able to ride my FJ1200 and MC parking was free.

Danny, any info about this event? Is it saturday and sunday?

Yes. It's in Rosemont a couple miles from O'Hare Airpotrt. I go most years.

http://www.motorcycleshows.com/city/chicago-il-0

wi.st.rod · « **Reply #824 on:** February 08, 2019, 07:53:37 AM »

Looking forward to seeing this progress.

News:

Author Topic: Sandcast #97 restoration (Read 216844 times)