Pedro!'s rebuilding projects

[Old Fogey]

I have an explanation for the change here:

http://www.wingovations.com/#/improved- ... 4556318365

This was a huge improvement in the redesign for the 78 engine. The new bushes give a full journal for the gear to rotate on, instead of turning on a journal that is splined for near half it's width. That was a dreadful piece of engineering design.
They also eliminated two of the splined thrust washers.
All in all a good upgrade, but to fit these to an early engine you need to replace the two gears as well since the bore is 1mm larger on these, or maybe the early ones could be bored out. The gears are toughened so that may not be easy as they would have to be ground out, something I have been intending to find out for a while now.

[Pedrotq]

G'day Gents!

well i have been home for a week of "Play Time" and back at work now, it is smashing down with rain here in Telfer (in the Great Sandy Desert).

well "bladredhead" and "Oldewing", i havechecked out the fairing that will go on my sidecar outfit from the wreck bike, it has a badge on the inside as follows;

[Pedrotq]

back again!

I could not work out how to add more text under the attached photo, so the story continues here.

well i completed rebuilding two motors, #4 which has all the worst and damaged parts, this i fitted into the frame of the bike that will be the tug for my sidecar, this way i do not have to worry about any damage done to the motor whilst tipping upside down and welding. #3 motor is good enough to be rebuilt, Pistons, Bore, Main and Big End Bearings all acceptable, just needs a gasket kit and piston rings fitted.

I was intending to have a pictoral description of the rebuild, I took a few photos and the camera went Brrr...Crunch...Crunch!!! when extending the lense out and now will not work at all, i did manage to take some poor quality pics with my mobile phone though.

i set up the bike and sidecar chasis to work out where and how to attach the sidecar without cutting up the fairing, but time ran out for me so this is how she looks now.

[Pedrotq]

and the story goes on. the break before last i wanted to dismantle the Final Drive units which I had 5 of as one bike came with a spare one.

as you probably know it is a frustrating job to undo the nut on the end of the pinnon shaft, and you need a spaecial tool to do the job.

So I looked closely at an old style drive shaft coupling that was worn out and noticed that the splines are cut right through! then a splined connector is peened into place. the tapered couplings of later couplings do not have this. so I machined off the peening, popped out the coupling connector, cut off the good half, bored out a hole on a square plate and welded it all together to a length of angle iron.

now I can slip the tool onto the splined pinnon drive and undo the nut with ease. I was so enthused at my new tool that I undid them all and stripped down the final drives without taking any photos (silly me).

[Pedrotq]

so here is a couple of old shots of #3 & #4 motors before I put the heads on them. as you can see #4 has had a welding repair to the rear enging cover, I believed it to be cracked from an over enthusiastic person larger than me trying to kickstart his machine with a jammed kickstart mechanisim.

during ther first round of aligning the sidecar up to the frame I realised that I need to cut off the heads of a bolt one each end of the removable section under the motor so as I could use a longer bolt, and also the bolt for the Left footpeg was too short, so i dismantled the machine, cut the heads off the two bolts, which was easy, but the footpeg one has a section of framework atop the head so i had to set up the frame on milk crates and blocks of wood on my drill press and drill down the center of the bolt and also a hole on the other side of the frame just under the right footpeg so as I can use a length of "Threadall" right through the frame.

well I am allways making mistakes so I practiced on the old sidecar frame and when I turned her upside down there was evidence of major welding repairs to the frame, so I guess this was in a serious accident sometime ago and not a jammed kickstart.

[bladredhead]

excellent. Rickman eh, i will keep an eye out i guess. thanks for the updates!

[Easter]

Fascinating, all four seem to be in decent shape compared to the junk I have been running across lately. Keep up the reporting.

[Kroosa]

Honestly Pedrotq, I am hooked. I can't wait to see what else you do. Taking on 4 bikes at a time has to be a record. I'm in the middle of restoring 2, and its a bit of a challenge, but both of mine were running so I am not going too far inside of the engines. Still, managing all the paint, chrome, cleaning, and carbs, and parts is a BIG DEAL. Good on you mate!

Looking forward to seeing more from you.

[Pedrotq]

Well my week off is now over and I am back at work.

I have a few pics for all to enjoy but it will take me a few posts to put them all up.

I had other things that got in the way of GoldWing play time, you know, mowing lawns, family get togethers, etc.

So here is my mudmap of how i am intending to fir the sidecar to the bike, I did this once to a Kawasaki Z-1300 but was in a rush as I wanted to ride the thing, I am in no hurry now and my plans will probably change as things go along?
Do the job once and do it right!

My camera is now working, I found the fault. My grandson has been swaping out the dead batteries for fresh ones for his Wii controls and leaving a box full of dead batteries!

More to come soon, Pedro!

[Easter]

It is a curious thing how Grandkids can get away with things our kids never could!

[Pedrotq]

Yes! grandkid's get away with blue murder sometimes, I just had to laugh when I worked it out.

So to fit the front lower mount I ground off the head of the bolt that holds the sub-frame on and replaced it with a longer bolt.

The lower mount will still need a mounting hole but i will set the chair up first and then drill the hole in the right place rather than make the arm fit the hole.

Pedro!

[Pedrotq]

Here is the lower rear mount. I cut the head off the bolt that holds the sub-frame so as I could fit a longer bolt, and I also drilled the bolt out that holds the Left footpeg, and also a hole on the coresponding side so as a length of Threadall can be slid right through the frame. I had to make a spacer to compensate for the left footpeg, will probably weld it onto the bracket later.

Pedro!

[Pedrotq]

Next was the other side of the frame. I do not want to squash the frame tube so I used a burr on a hand drill to carefuly widen the outer hole so as I could place a spacer tube in so as some of the force will rest apon the inside of the frame tube as well.

More pics to come, just got to do some work here at work.

Pedro!

[Pedrotq]

Strip the bike down, set the frame up for a little weld. I am not a welder and on practice runs on scrap i do burn holes so i did little tack welds all around, I think I did ok and she will hold and do the job.

Re-assemble the bike again and put the new firttings into action!

Pedro!

[Pedrotq]

Now for the lower sidecar mounts, the one that came from her was not quite 90 degrees, I will be buying a pipe bender next break and making my own. the end joints I was thinking of using plumbing fittings obtainable from our local hardware store and machining them to do what I want them to do.

This is just a start and I am sure things will evolve and change a little.

Pedro!