no not a chainsaw

[dobbslc]

Nice work!
Those rods look very long compared to anything modern!

 

[zeppelin builder]

Nice work!
Those rods look very long compared to anything modern!

add a big heavy cast iron piston long stroke
high piston speed ,its a wonder they got past tickover speeds

 

[zeppelin builder]

good job i checked the rod i dont think it would have lasted heres some more pictures clearly showing a defect under my magnifier
been reading about an old harley tuner
Jerry Branch ,who developed the kr racers
and he used to cut and weld rods regularily
so il give it a go il pre heat and post heat,
and i will use ,er 80 filarc 6513 which is almost the same as the rod its got nickle,
iron ,manganese and silicon
most of the people who have done it used er70s2 wire nothing exotic

 

[zeppelin builder]

heres the conrod from the start first indication of a crack
then a bit more cleaning and dye pen
next excavation and more dye to get it all oot
next degrease and pre heat to 200c weld using 1.6 pz6513 on completion peen weld put in preheated oven and bring down slowly
blend weld toes warm up and soak in dye
no visible defects

as i have a dirty great DC magnetiser i thought id do some more ndt namely Mpi dc can also show subsurface defects

so rods were coated and i sprayed them with the developer in both planes and happily i had no indications

checked the rods for true then built up the crank
welded up the cam followers with haynes ultramet £££ and profiled to same as 1 good one
set up the cams all 3 of them
them sorted out and motored the oil pump to check
so bottom end all built fingers crossed
top ends coming soon its originaly 550cc
but it will be just short of 600 with the 2mm overbore

 

[zeppelin builder]

got the modded Kubota d722 pistons and rebored barrels back tonight excelent job
il put it together sans rings tommorow and chuck in some blue tack to check squish clearances and check top ring dosent run out of bore on the breathing side

 

[zeppelin builder]

fitted up the pistons and had to chamfer the tops to suit the chambers ,it worked out well and the top ring is safely out of danger
there is a couple of mm above clearance
ive removed the expanders behind the oil control rings to give it a bit more oil
the pistons protrude about 7mm at tdc so will give it a bit more compression and squish
its all nice and free too so thats a good sign

one of the exhaust valves was a bit short so i tigged about 5mm on the end with 309 and gave it a dollop of stellite

next is overhaul the schebler carb it looks pretty simple and redneck proof only bad bit is the old cork float

 

[zeppelin builder]

the old cork float looked a bit past it so i soldered a new Tecumseh brass one to the hinge part , bike is together and runs very crisp ,tickover is a bit unreliable due to wear in the butterfly spindle , so thats another job bushing and reaming the new parts
just addressing all the wear on linkages
we got another wheel with wired on tyre so m gaurd which is not original will need modded And forks will need overhauled and spindles freed and greased

 

[Screwdriver]

Wow. That's some seriously impressive restoration there.

 

[zeppelin builder]

heres the matching wheel
had to notch the gaurd and pull it in to a suitable radius , shorten the stays and stand its nearly there im goint to shorten it at both ends and relocate the stand clip its been a lash up made from two ,got the bits for carb from sweden , and got the forks freed and lubed so another leap forward
so much for itl take a week thats a month so far
gonna be a sweet wee bike ,

 

[Migmac]

heres the matching wheel
had to notch the gaurd and pull it in to a suitable radius , shorten the stays and stand its nearly there im goint to shorten it at both ends and relocate the stand clip its been a lash up made from two ,got the bits for carb from sweden , and got the forks freed and lubed so another leap forward
so much for itl take a week thats a month so far
gonna be a sweet wee bike ,

Think I recall you saying it was going to be a quick job

 

[zeppelin builder]

went to fit the new carb spindle and bushes
and check the float height , turns out the float was full of petrol and sinking , put the float in a glass full of near boiling water and was rewarded by a fine jet of petrol in my face this showed up a bad seam joint which was fixed with a quick remelt and some bakers fluid
its coming on near complete soon finished the front gaurd and stays so its make a rudimentary wiring loom and try and incorporate an electronic dynamo regulator
then i will do a few miles on it and fine tune it

 

[zeppelin builder]

had a ride on it very smooth and id sah it wants more advamce thats squish for ya
miles more effiecient , hate them twist grip contols tho like wringing an old dishcloth


only fault is oilpump leaks like a sieve , jb weld amazingly did not cure it donald , so timing cover off to get to one screw

 

[Tifa]

Wow!!!
Late to thread...but now subscribed!

 

[zeppelin builder]

fitted brand new bronze bodied oil pump no more oil leaks , replca,bosch lighting and horn are very poor quality rear light had a dead short as no insulation on the live spade and fancy klaxon shows open circuit on its terminals ,,need further investigations

 

[zeppelin builder]

horn was an easy fix , someone had nicked the innards , managed go get a thirty bob chinese one inside though
took bike out for a ride but after stopping with the back brake it refused to move forward , went back wards ok so stripped the drum off and there was a pair of brake shoes that somebody had made out of steel
only thing was there was no return spring on the cam side ,more khaki paint was evident
too so probably some field repairs
il fit a spring and it be ok
its having a problem with random flooding
and ive tried everything i think the float is fouling inside the carb
so im awating a needle and float from over the pond
and that should be it done