'78 - pinched another loaf - Johnny 5!

[pidjones]

These are the 16 screws that were holding the float bowls on. Need to order some more Helicoils!
Where's Waldo for tonight - can you find the correct screw?

DSC07972.JPG (182.29 KiB) Viewed 262 times

[CYBORG]

Top left. second one. The only one with standard threads

[rcmatt007]

When I tore down my LTD, the cross member for the center stand had holes all across the bottom

[pidjones]

Discovered the carb rack on this '78 is actually from a '77. Got the piston out of the rear MC and the rest looks Ok. Helicoil kit came in so I can repair the 15 out of 16 float bowl screw threads that had sheet metal or wood screws in them. Took the frame and a '79 frame to a buddy's who will cut the center stand mount cross member from the '79 and weld it to the '78.

[pidjones]

16 Helicoils in for the carb float bowls. Buddy just called and said that my frame has been repaired.

[pidjones]

Oh yeah! Rick did a great job on the frame. Cut the old bad section out and corresponding section from the donor frame (including the gussets) and welded them in. As soon as I got it home, I wiped it down with alcohol and hit it with some etching primer in the repair area. Took the front MC apart and was able to just clean it up and put it back together with the original pistons and such. Seems to be fine. Just had to make a new reservoir o-ring for it. While at it, made a new reservoir o-ring for the rear MC. Kit for the rear MC came in today, so I have all of the parts except for front brake hoses to do all of the braking system. Also have everything to assemble the carbs, but I'm waiting to see what the rack that a guy is giving me looks like. It is a '78 set so should work with the engine better. Been thinking about maybe a two-tone when painting the plastic weather gets here.

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DSC07978.JPG (85.47 KiB) Viewed 198 times

[pidjones]

Actually, build date for this '78 is September '77. Wonder if 764A carbs were on it from the factory? Although, the FSM sez they would be 769As.

[Liam]

That is a really neat frame repair.

[Track T 2411]

That is a really neat frame repair.

I was thinking the same thing. Obviously done by someone with 'skills!'

[pidjones]

That is a really neat frame repair.

I was thinking the same thing. Obviously done by someone with 'skills!'

A retired nuclear welder from near Oak Ridge. He said it was a fun challenge.

[pidjones]

These fence row bikes are a challenge! Yesterday, I finished cleaning and assembling rear caliper, both front calipers, and the rear master. Also cleaned the contacts on the fuel gauge pickup, drained the tank, sprayed it with fogging oil, and stored it in the shed. Pieces slowly getting ready. Striping and painting still to do, but I'm constrained by weather since most of that has to go outdoors. Might dig out the harness and start on it soon. At least I was able to reuse the rear caliper pistons by mounting them on the lathe and spinning with brake cleaner soaked Scotchbrite held against them. Lots of crud, but no pitting! Used a brass brush in my moto tool to clean up the caliper bores and piston ring grooves. Just wadded up aluminum foil and brake cleaner for the master bores (guitar string for the relief holes).

[pidjones]

Spent the morning cleaning, removing rust with the wire wheel in the drill press, taping off the motor in preparation for Gunk treatment (when it warms enough for me to take it outside for the hose-off). The clutch actuator cover was missing from this one. Luckily, I had one from the junker, but had to add gromets and center tubes that make the bolts that hold it on like "setting bolts" - made from left-over bathroom plumbing parts. The rear tire on this is "just" a ten year-old Dunlop. I might just leave it, replace the front, and warn any buyer that a rear is due. I cleaned the rear hub and wheel. Still need to clean the rear drive and swingarm, which is always fun. I guess the wiring harness needs to get laid out and gone over next. Not much else to do until weather changes. That could be next week or four months the way East Tennessee weather goes.

[pidjones]

Just had a USPS delivery - a '78 rack fom 78wingman! Will need need ceaning and parts swapping, but it is a correct '78 (31mm) rack instead of the '77 (32mm) rack that came on this one. A few parts will come from the '79 junker rack that I had stripped down and stored away "just in case". Now, to loosely assemble the '77 rack so it can be stored (and so I can use the plastic shoeboxes it is in for the '78 parts). Then, the '78 hits the US bath.

[pidjones]

Well, the '78 rack was a bit beyond repair - too much corrosion. So, I assembled the '77 rack with '78 spec jets (60 primary fuel and 120 slow air). While waiting for some o-rings, I took an old right plenum half, cut it in half, plugged the cross-passages, and used it for leak testing the carbs individually. Now that I have the rest of the o-rings, the entire rack is now assembled and leak testing. I use isopropyl alcohol for testing as the garage is in the basement of our home.

carbs under test.jpg (145.27 KiB) Viewed 118 times

[ritalz]

Using alcohol may help keep the peace. I'm not too good at that.