Author Topic: Sandcast #97 restoration (Read 205146 times)

markb · « **Reply #825 on:** March 08, 2019, 07:57:50 AM »

My latest project is working on restoring brake disks. For now I have a NOS K1 disk until I can replace it with a correct restored one. I made a special tool for grinding the disks on a surface grinder.

I’m still experimenting but here’s where I am so far. Before…

…and after.

If you’re interested here is a thread that shows a little more detail about what I’m doing starting at reply #45.
http://forums.sohc4.net/index.php/topic,175601.25.html

SOHC4 Cafe Racer Fan · « **Reply #826 on:** March 08, 2019, 09:09:23 AM »

From what your tool looks like, your grinding not only takes out wear but can also address any warping. Can you also "thin" the rotor surface to lighten the disc?

markb · « **Reply #827 on:** March 08, 2019, 02:53:47 PM »

I think that's correct. The outside of the disk is now parallel with the mounting surface on the hub. When I flip it over to do the inside, the disk will be sitting right on the turntable so both side will be parallel to each other. I haven't done that yet. I'm going to wait until I get a courser wheel.

The wheel is thinner after grinding but not much. I only took about 0.005" of it. It would take a while to lighten it with this method.

Can550 · « **Reply #828 on:** March 08, 2019, 05:17:10 PM »

Like it a lot

Sent from my iPhone using Tapatalk

Stev-o · « **Reply #829 on:** March 12, 2019, 06:44:01 AM »

Looks great!

Godffery · « **Reply #830 on:** March 12, 2019, 07:41:59 AM »

Quote from: SOHC4 Cafe Racer Fan on March 08, 2019, 09:09:23 AM

From what your tool looks like, your grinding not only takes out wear but can also address any warping. Can you also "thin" the rotor surface to lighten the disc?

I provide a drilled & Thinned Rotor service if your looking for lighter. (Roughly half the weight of stock)

https://godfferysgarage.com/wp-content/uploads/28336422_332195967288423_6739062907242179043_o.jpg

markb · « **Reply #831 on:** May 20, 2019, 07:07:40 AM »

I’ve finally finished restoring the brake rotor. I think it turned out pretty good. The masking was a challenge because of the spokes and the rivets on the inside.

I tried different tapes and trimming with an exacto knife but couldn’t get decent results. I finally made a tool that has a hole the same size as the diameter of the rivet with a flat land around it.

Then I drilled the same size hole on the other end and machined an angle to make it sharp.

After trying masking tape, vinyl tape and some others I found that the tape that worked the best was duct tape. The flat end of the tool formed the tape around the rivet head.

Then the sharp end trimmed the tape perfectly.

Here’s a pic of the finished product on the outside…

…and the inside. Now #97 finally has a correct rotor!

SOHC4 Cafe Racer Fan · « **Reply #832 on:** May 20, 2019, 08:59:20 AM »

Nice detail solution.

markb · « **Reply #833 on:** June 01, 2019, 06:55:27 AM »

IT RUNS!!

I took #97 out for a short test ride last night. It’s tuned up, carbs synced and sounds great. I only went about a mile. Ran it up to 60 and through all 5 gears. Everything works. I have about a 15 second video (28MB) of it running that I would like to post but not sure how to do that. Can anyone point me in the right direction?

fastbroshi · « **Reply #834 on:** June 01, 2019, 07:21:52 AM »

Youtube might be the easiest way, or maybe Imgur. Not sure if you can upload vids there though.

markb · « **Reply #835 on:** June 04, 2019, 06:21:31 AM »

I think I got it to work. Click on the link below. It's a short video. I'll try to post a longer one later. But at least it proves it runs.

Tews19 · « **Reply #836 on:** June 10, 2019, 08:07:34 PM »

Excellent work! She sounds very smooth!

fastbroshi · « **Reply #837 on:** June 10, 2019, 09:26:31 PM »

I must be getting old, because wow, that sounds good even with a quiet exhaust.

markb · « **Reply #838 on:** June 11, 2019, 12:29:29 PM »

It's not as quiet as it sounds on my phone. I plan to post another video showing it rolling down the road and I'll get a good shot from behind.

markb · « **Reply #839 on:** June 16, 2019, 12:27:09 PM »

I decided to take #97 to a show (one of the reasons I wanted to make sure it runs).
It was a pretty big local show. There was close to 200 bikes there. After I saw the picture on the flyer I knew I had to bring mine. Both the local chapter of the AMCA and the local chapter of the VJMC were there.

Here’s a pic of it on display. It was nice that they put it on a stand right near the entrance. It definitely got a lot of attention. I was hoping it would do well.

It did better than I could have hoped for. The local VJMC has cool trophies, large, nicely polished and chromed metric wrenches. I got one for Best In Show.

The AMCA was also judging and I got the Junior First Award (first time entered) with 100 points!

They did comment about the chrome finish on the taillight bracket but didn’t deduct any points. Maybe it helped that in was the 50th anniversary for the bike (to the month) and the only sandcast there.

The icing on the cake though was the editor of the AMCA magazine was there and took pictures of #97.

He said they will be in the September/October edition. So like I said I couldn’t have asked for more. I feel very lucky and grateful for all the help I’ve gotten from the SOOC and SOHC4 sites. Thank you guys for all your help and support.

So I got the bike home and drained the gas tank, petcock bowl and carburetor bowls. I blew air down the fuel lines (lightly) with the drain screws loose and cranked the engine over for about 10 seconds (it ran for about 2 seconds) to try to suck any last gas out of the carbs. I don’t even know if that does anything, it just seemed like a good idea. Short of actually removing carbs and cleaning them is there anything else I should do? Should I actual pull them or not? It might be a while before the bike runs again. Although after the success this weekend I am toying with the idea of going to Barber.

MauiK3 · « **Reply #840 on:** June 16, 2019, 08:09:43 PM »

Wow, the #97 legend continues!
What an inspiration, I’m wondering where I could get my hands on a sandcast now, dangerous.

SOHC4 Cafe Racer Fan · « **Reply #841 on:** June 17, 2019, 10:02:01 AM »

Congratulations! The bike looks amazing.

markb · « **Reply #842 on:** June 18, 2019, 06:10:44 AM »

Thanks guys.

Quote from: markb on June 16, 2019, 12:27:09 PM

So I got the bike home and drained the gas tank, petcock bowl and carburetor bowls. I blew air down the fuel lines (lightly) with the drain screws loose and cranked the engine over for about 10 seconds (it ran for about 2 seconds) to try to suck any last gas out of the carbs. I don’t even know if that does anything, it just seemed like a good idea. Short of actually removing carbs and cleaning them is there anything else I should do? Should I actual pull them or not?

Anyone have any comments about my storage preparation? I was also thinking about fogging the cylinders, maybe changing the oil, etc.

MauiK3 · « **Reply #843 on:** June 18, 2019, 08:26:53 AM »

I've never prepped a motor for storage but I wonder if actually putting a puddle of light oil on top of each piston would help keep rings free.
I always worry about the cam and top end getting dry.

markb · « **Reply #844 on:** June 20, 2019, 06:11:33 AM »

I would think that fogging the cylinders would take care of that. The other thing I was thinking about was draining the brake fluid. It's easier to add the fluids rather than clean carbs, master cylinder, etc. later. I'm just not sure when I will start it and ride it again. I've even thought about the possibility of selling it.

MauiK3 · « **Reply #845 on:** June 20, 2019, 09:09:17 AM »

Brake fluid, hmmmmm. I never thought about it.
I wonder if leaving fresh fluid in for long periods is better than the system being empty. Would the o rings and piston dry out?
Hard to say, I bet someone knows in the classic car world.

MauiK3 · « **Reply #846 on:** June 20, 2019, 09:09:58 AM »

As for selling it, if you do, hopefully it finds a good home.

nvr2old · « **Reply #847 on:** June 20, 2019, 09:14:18 AM »

All one needs to to do is to go back to the opening page on this thread for a slap-in-the-face realization of the amount of work that you put into this bike. A truly amazing transformation. You are to be commended. To go through that amount of work only to sell it seems sad to me, though. I know it's worth a ton of money, but you should also be able to enjoy the fruits of your labor. Ride it, love it, and take care of it for future generations.

Old Scrambler · « **Reply #848 on:** June 20, 2019, 04:11:16 PM »

Just catching up a little with your excellent project................I have successfully stored my K3 for longer than a year with the tank and carbs full of race-gas............fog the cylinders.....but more important........turn the motor a little to move the rings and prevent any cylinder etching

BTW.......there will be a 'bigger' party at VMD in Ohio from July 4th to 7th............and you could have the bike judged again by the AMCA at the Davenport Chief Blackhawk event just before Labor Day.

markb · « **Reply #849 on:** June 20, 2019, 04:39:45 PM »

Quote from: MauiK3 on June 20, 2019, 09:09:17 AM

Brake fluid, hmmmmm. I never thought about it.
I wonder if leaving fresh fluid in for long periods is better than the system being empty. Would the o rings and piston dry out?
Hard to say, I bet someone knows in the classic car world.

The bike sat for about 3 1/2 years and the brake fluid had gone bad. Not sure if that is typical or not.

Quote from: Old Scrambler on June 20, 2019, 04:11:16 PM

BTW.......there will be a 'bigger' party at VMD in Ohio from July 4th to 7th............and you could have the bike judged again by the AMCA at the Davenport Chief Blackhawk event just before Labor Day.

I thought about trying to make it to Ohio. Unfortunately too much family stuff going on so I can't.

Thinking about Barber though.

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Author Topic: Sandcast #97 restoration (Read 205146 times)