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!