We started the last session by finishing off the suggested jetting changes.  The last piece of the puzzle was to switch to a size #25 pilot jet.  Once again the float bowl was removed and the correct jet installed.  So with a new needle, main, and pilot jet, as well as a new needle seat, we should have a good spot for a baseline to do fine tuning... when the bike gets running!

We have also come to realize that the side numberplates of the Manx seat won't work with our choice of intake manifold... and for a few other reasons, we also decided to eliminate the side plates from our seat. These have to be removed slowly and carefully, so the Dremel tool was fired up once again. 

Steady as she goes... note the mask and eye protection!

While the seat was getting trimmed, Mr. S finished welding the new seat mount to the frame, after being tack-welded in place previously.  Once alignment was checked and re-checked, we went ahead with the permanent solution.  Next, the remaining mounting holes were drilled once marks were made.

Over the weekend, Mr. S bought some slip-fit exhaust pieces from Canadian Tire as a trial fit for the exhaust.  This solution appears to be workable, so the plan is to weld extensions on to the current pipes, so that the megaphone exhaust will clear the rearsets, as well as the rear axle.  The end result won't look pretty, so the headers will have to be stripped and refinished somehow.

Over the next while it is finally time to tackle the wiring.  Not sure how things will go... we've got the original wiring diagram to go by, as well as several examples of solutions others have found incorporating the more modern components like our Pamco kit and PMA alternator.  That, combined with the use of the stock handlebar switchgear, as well as safety requirements, will be a test.  Might as well dive right in!




 

 

 



Seatwork

While a student and I did some work on the carb and throttle cable (version 3), we installed new exhaust gaskets and took another stab at fitting the exhaust.  Once again, it appears that the system will not work "perfectly" with a drum brake model machine -- the splined shaft that actuates the rear drum brake will foul on the exhaust megaphone.  Again, we need to think on a solution.

We then went about fitting the new gasket to the crankcase breather.  Some gentle surface prep was required.

Next we went to work prepping the cafe seat for fitment.  We haven't done anything permanent as we really needed to see where and how it could be best fit to the frame itself.  We will use the "stock" mounting points, so the three holes were drilled to orient this part to the frame.







Now that these have been determined, once we had offered it up to the frame, located it with the seat foam and shorter than usual tank, it became apparent that using the traditional mounting location was not going to work.  As a result, we will have to mount a new plate onto the frame to locate the seat.

Mr. S had brought along his welding kit, and some steel plate, and we set about cutting and measuring an appropriate mounting plate.  At this point we are not done (yet), but it was interesting to note how "long" it took to properly make the plate, and we haven't even attached it yet!  Mr. S will come in after school to do some welding to the frame, based on the work the students have done to date.  Accuracy is key!!!

Back at It

After the Christmas break we were eager to get back at the wrenching.  A number of parts had come in over the holiday, and Mr. S brought those along to the session.

Step One for this session was to test-fit the exhaust system.  No instructions were included, so some trial and error ensued. 

The end result was that the headers fit properly, but it appears the location/outlet angle of the 2-1 collector will foul on the rearset.  This is typical with any custom build.  Basically, we will need to do a bit of "thinnin'" to come up with a solution. 

We spent the remainder of the time test fitting the rear fender, and custom-making a throttle cable.  We worked on some measuring, cutting, and soldering techniques.  Honestly, it took quite a while, and the whole process was a bit fiddly.  In the end, we got a throttle cable cut and fabricated, but the "Option A" routing left the throttle action a bit stiff -- too long, and too many bends.  The "sidewinder" intake is very cool and unique, but causes a bit of a problem with cable routing.  We will have to try "Option B"  which means re-doing the cable.  Again, some reality therapy for the students.  This would not end up on American Chopper!

Finally, a big shout out to Tim Aysan.  A fellow Canuck, he donated a spare crankcase vent for our project.  Tim is a Cafe fan, and runs www.dotheton.com.  Be sure to check out their site if you can.  Thanks Tim!