Now We're Rolling

Now it feels like I'm really making progress. With a day off for Memorial Day I decided I'd better make some progress on the Cub so I assembled the fork and mounted it, along with the wheels, to the frame to complete the rolling chassis. I had a few problems but you can see the final results. I'm happy with the way things are looking and can't wait to get more work done.






I'm putting together a list of parts I'm going to need to get the engine back together.  That will be the next endeavor.  There is still a long way to go but having a sub-assembly complete is very motivating

Frame Assmebly Time

FrameAssembly1
Originally uploaded by Gym_x

I planned this post to be a shot of the before and after pictures of the shocks since I spent quite a bit of time rehabilitating them, but I got on a roll and started bolting things together last night.

Since I'm working by myself and didn't have three or four other hands to help hold things I strapped the head to my shelving with the frame sitting on a make-shift work table (a cardboard wardrobe box with a piece of masonite for a top). It isn't perfect and would have been better if I'd have built some sort of frame holding jig, but it got the job done last night.

What you can sort of see in this picture is the completed frame with the rear sub-frame and shocks mounted. the fabricated bushings are great and everything bolted up with only a few headaches. For some reason the rear sub-frame shrank, or was bent, between disassembly and assembly. I had to put the lower bolts in then really pull on the top to get the upper mounting stud in place. I don't remember it being difficult to remove but it was quite a while back - November 2008.

I'm really happy with the results so far and can hardly wait to get the fork reassembled and the wheels on. You can't tell from the cluttered picture but I've actually cleared a spot for the rolling chassis to wait for the engine work to get finished - started first, then completed but you get the gist.

I'm energized to get things moving along more quickly on this project now and need to get on top of ordering parts for the engine work. I only need a few pieces and some gaskets to get thngs moving forward. I'd better get on that.

One more shot of the frame from another angle.



FrameAssembly3
Originally uploaded by Gym_x

Rear Shock - Before

Just a quick teaser. This is a "before" picture of the old shock. You've already seen before and after of the bushings. The whole enchilada is next.

Originally uploaded by Gym_x

Can't Beat These Bushes

New and Old
Originally uploaded by Gym_x

I got my rear shock bushings fabricated this evening and am very happy with how they turned out. The material I got from McMaster Carr was perfect. It seems to be the right hardness, was the right O.D. and wasn't too bad to cut to size and drill to fit the spacers. Only time will tell how it's going to hold up but for the price of two bushings I can make two complete sets for my bike and have some material left over.

I'm painting shock bodies now and will get them reassembled this weekend so I should have a roller by Sunday night, provided I can get a few hours in the garage this weekend. That's provided the leak from my Jeep's radiator doesn't get worse so it takes a higher priority.

The photo shows one pair of the old bushings along with the new ones and the rest of my raw bushing material.

Rear Shock Bushings

P5180048
Originally uploaded by Gym_x

I'm almost ready to assemble the rolling chassis. I'm putting the finishing touches on the rear shocks and the forks now.  Once those are finished I'll be ready for assembly.  The fork gaiters arrived last week and I'll get those mounted this weekend to complete the front.

In the back I'm refinishing the rear shocks and, as you can see from this picture, the bushings are shot. The left is the bushing from the bottom of the shock after it was removed. On the right is the internal spacer from the other side after cleaning it up. I've got some material that's the right outside dimension for the top and bottom and all I need to do is put the right sized holes into it and I'll have bushings as good as new. I hope to get that done this weekend as well.

Hopefully, my next post will have pictures of the rolling chassis.

Frame Painted

I've got several coats of beautiful glossy black paint on the frame, swingarm, sub-frame, side stand, foot rests, and a few other miscellaneous parts. I’ve got the wheels assembled with their old brake shoes – new ones on order. Forks are painted and assembled minus their oil, which I’ll add when I’m closer to having a running engine. Here’s a shot of the rolling chassis. I’m pretty happy with her so far. I chose to paint the frame myself, rather than powder-coating, because: a) I wanted to do as much of the work myself as possible and b) it’ll be easier to touch up, although probably easier to chip in the first place.

I’m sealing the tank next. Get the caustic chemicals over with before putting on a nice coat of paint so as not to wreck it when they leak all over, which they’re sure to do. With that, and some fort gaiters I’ll be in pretty good shape.

I’ve started making a list of engine parts I MUST have and those I would probably replace if money were no object. I really don’t want to do an engine rebuild a few months after getting it all back together so I’m trying to achieve a balance between expenses and long-term investment/rework. I suppose this is the classic struggle between the wallet and the wrench.

I’ll get some parts ordered and use the time it takes them to arrive to build myself an engine stand, polish up the side covers, and brighten up the cases, head, and barrel. I can’t get the barrel to look as nice as I’d like so I’ll likely paint it. I’ve seen a lot of Cubs with black barrels and I like the way they look. I hesitate to give myself any sort of schedule because I seem to miss every deadline I set for myself but I’m shooting for an assembled engine by the end of May. We’ll see how that plays out.

FINALLY, moving ahead again

I didn't get anything done last weekend as I had planned. I blame the rain but I could have painted in the garage. I didn't want overspray on everything so I opted out. I was busy with a lot of other stuff so I'm using the rain as my excuse for the week.

This weekend I got started early, Thursday actually. I managed to get things setup in the back yard and sprayed the rear sub-frame, sidestand, and pillion support (one of them). They turned out pretty well. I'm using Krylon from a can and am trying to be as patient as possible, spraying multiple light coats with a bit of drying time between each. This method seems to be working so I'm sticking with it. I think I'm going to tackle the tank and fenders using this method too. I'm getting ahead of myself.

Last night I started spraying the frame. I'm being even more careful with it as more of it is going to show when the bike is back together. I sprayed one side and the top last night. I'll be spraying the other side and the bottom later this weekend. It's supposed to rain again here tomorrow so I'm hoping to spray some again today. Who would have thought that RAIN would be hindering my progress HERE, IN PHOENIX! We get an average of 9 inches a year. That's effectively none but it's falling at the wrong times for me.

Oh well. I'm making progress again and feel good about it. I'll get some pictures and will post them soon.

Safe riding.

Time To Get Moving Again

Frame
Originally uploaded by Gym_x

I hate to make plans for the weekend but I'm going to anyway in the hope it will motivate me to act. Saturday morning I'm going to setup a temporary paint booth in my back yard and start painting the frame and sub-frame. They're all primed and ready so all I need to do is wipe them down and start spraying. If all goes well, by the end of the weekend I'll have a painted frame, ready for assembly.

My aim is to get the rolling chassis assembled. I don't have the fork gaiters or new brake shoes yet but I can add those later without much disassembly required. The other decision I've made concerns the engine.

I'm going to rebuild the engine and only replace the items I know to be in need of attention. That means, new main bearings for the crank, new valve guides, new piston rings, and that's it. I should be able to get all the parts I need without spending a lot so that will help move it along. I'm planning to do the work myself because I'm not doing any machining. We'll see how it goes. If I get stuck I can always go to a pro. I'm pretty good at recognizing when I'm over my head before doing any damage.

Ok, there's the plan. It's 'out' so I have pressure to follow through. I'd love to have this little bike running in a couple of months. If I don't run into any real mechanical issues with the engine I think that's possible. I've done all the reconditioning of the parts as they came apart so it really is ready to reassemble.

In case you forgot what the frame looks like here's a beauty shot. Wish me luck and stay tuned.