A sign of life!

Well, sort of.  We had our first day of wiring work, and we met with some success.  Armed with our wiring diagram, we started the process.

What a tangled web we've weaved!  Starting from the handlebar switchgear, we moved our way to the rear of the bike, which housed the battery, fuse box, regulator/rectifier, and turn signal relay.

The other end...  The first item we got to work was the horn, once we figured the switch itself was grounded to the handlebars.  After turning on the main switch, we got the first "beeps".

Next we set about working on the headlights.  At first they didn't work, until Mr. S remembered that the fuse box only works when there are fuses to complete the circuit!  You can see the 10amp one in place to the left.

While it looks a complicated mess, we actually got the lights to work, both low beam and high beam!  However, they came on as soon as the main switch (the key) was turned on.  We don't want to drain the battery, so we need to figure out how to wire in the on/off switch on the RHS handlebar switch.  That will take some thinking.

This is how we left it.  Of course, when we do get everything working -- the brake light switch, the turn signals, the dash light, and a spark, we will use proper connectors, and clean the assembly up "proper".  Mr. S will need to visit NAPA or some similar store to get quality block connectors to go with the blade connectors we have already.  We want the assembly to look "factory" and also be reliable and watertight.
We will miss next week due to spring break, but will carry on in April.

Back at it

With a few more Cafe sessions missed due to busy students, and Mr. Sheppard forgetting the camera on one occassion, we had another session on the 12th of March.  The main goal of this session was to finish mounting the electrical components so we could begin the wiring process.

Here a student drills the mounting hole for one of the brackets.  We have hopefully come up with a way to hide the regulator/rectifier under the seat with a sturdy aluminum mount, while still giving it enough clearance to stay cool... this component has been known to heat up a bit.

Trying to get everything lined up square, even though it will be hidden under the seat hump, took some figuring.  Hey look!  This is why we learn how to divide fractions!  What is half of 8 1/4"???  Fuse box will be mounted just ahead of the battery. 

Intake manifold/carb solution #3... third time is a charm.  The folks at Wiseguys Choppers thankfully exchanged our radical intake with something a bit more traditional, but still utilizes a single carb.  For the sake of the kids, Mr. Sheppard fabricated the custom throttle cable on his own... this was #4, and hopefully the last!

Next session, we will start to wire the bike!