More Wiring

With the signals working, the next step was to try to clean up the wiring a bit more. 

With some fiddling with wires, we were able to produce a spark, so at least all of the ignition components are in working order.  Next we need to ensure the switches work as they should.

 The next step was fabricating a proper muffler mounting strap.  A fairly straightforward process, but it did require some accurate measuring and drilling to make sure the two mounting bolts lined up properly.

Next we began the process of fitting the front seat mounting studs.  Like the rear battery tray, we are going to weld in some shouldered m6 nuts into the frame rails, and then fix the front end of the seat in place.  The holes were drilled and the nuts put in place; Mr. S will come in on another day and do the welding.






Finishing the wiring will be the next step.  Tedious, and in fact Mr. Sheppard came in on his own a couple of evenings to work on things.  Really, at times a one-person job due to the cramped nature of the bike. 

Signals next

We snatched victory from the jaws of defeat.  After spending most of the session flicking the turn signal off and on, we came to the conclusion that the turn signal relay was not the right type for our application.  We got a "click" out of the relay, but no lights.  Not knowing a lot about relays, we guessed that there might be too much resistance in the relay unit, and decided to try something different. 

While Mr. Sheppard rooted around the boxes of spares for another relay, the tailight mounting bracket was modified to accept the turn signals.

With the signals then mounted in the bracket, and everything re-attached with the replacement relay (over 40 years old), we got ready to test again.  Note the size of the turn signals.  These are DOT approved.  Yes, very large, but we don't want any hassle when we go to get the bike saftied.  The new owner may swap them out for something smaller...
The student in the pic is grounding out the terminals on a bare part of the frame.

Left.... got it!

And the right one works as well!  Next up, ignition system.  We will search for that elusive spark, and then go about properly bundling and connecting the wires in the harness.

Slow and Steady Progress

The April 2 session saw some more tangible progress for the bike project.

A "new to us" (used) exhaust system was sourced which works better with our cafe rear sets.  It is a MAC 2-1 system.  We will need to fabricate a muffler mount, but everything appears to work as it should.

Next we went about tacking more of the custom wiring harness.

Using a heat gun to heat-shrink tubing once connections have been made.

Soldering connections.  Always nice to have a second pair of hands.  Watch out where the melted flux falls, as it can be corrosive on painted surfaces.

Fitting proper battery terminal connections, as well as prepping the connectors that fit into the fuse box.  Need to get everything water-tight!

Tail/running light.

Brake light.  Whoo hoo!

To date, we now have working headlight, tail light, brake light, instrument light, and horn.

Next step is the turn signals, and finally the stator/rotor/alternator/ ignition system.  Gotta get that spark!

Next cafe session is April 16.

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!

Grinding, Drilling, and Welding

We didn't have a full 2 hours today as the students scheduled had to head to the rink for hockey practice.  However we made most of the afternoon, as we were able to work with some pneumatic tools to advance the project.
Last week saw us put together the rear tail light assembly, combining parts from pre 1977 and post 1977 models.  We hit a minor roadblock as the socket for the tailight bulb fouled on the mounting bracket.  Some short work with the die grinder solved that.  Thanks to Mr. Gugin for the use of the tool -- setting up, as well as lending the protective equipment!  The light now fits in the bracket so we will reassemble the parts to test fit next time.

Next we needed to drill holes to set nuts into the frame rail, in order to mount the aluminum battery tray/fuse holder/fender.  Mr. Sheppard had taken the cardboard cutout and fashioned an aluminum equivalent, which you can see on the edge of the workbench.  We need to drill...

Locate the nuts in the holes (shouldered nuts work great here...)

And then weld them in place.  Note that not a lot of filler is needed, as these really aren't load-bearing nuts.  The bolt on the left hand side was used to ensure the nut was square to the frame.  Once everything is cooled, we will remove the bolt, and then use a die to chase the threads to make sure they will work with the appropriate bolt.  Much better than aluminum riv-nuts, which are another option.

Finally, the boys get a look at the wiring diagram.  It looks complicated, but with some patience and trial and error, it will work.  Big thanks to xs650.com forum member "jayel" from Southwestern Iowa, who made the diagram for us to use.

Back at it

January has been a bit of a hit-and-miss month with the project, as many of the students are also involved with basketball and curling, both of which also fall on Tuesdays.  The start of Februrary sees these activities wrap up, so kids are become more available to continue working on the bike.

A bigger job for this session was stripping the wiring harness in order to start from scratch.  As mentioned previously, the entire bike will be re-wired, from scratch, mating 40-year old handlebar controls with a modern ignition system, regulator/rectifier, and blade fuses.  Took almost the entire session, but with patience, the harness was stripped and we should have enough wire (in the right colors) to connect all the component parts.

Part of what makes a Cafe bike "trick" is to create the clean look.  The advantage of our seat section is that some bulky parts, like the batter and other components, can be hidden under the seat hump.  First step is to trace... you can see the student in the background utilizing some scrap cardboard and a steady hand.

And then we cut!  This piece will be traced onto an aluminum sheet and cut out.  It will act as a inner fender, as well as allow a spot for the battery box to be mounted, and will also provide some "real estate" to mount the fuse box and perhaps the regulator/rectifier.

While this was going on, another student worked on the front end of the bike.  The top triple clamp needed to be removed and the new headlight ears installed onto the forks.  Once done, this allowed the front end to be finished up in terms of the front suspension.

Once done, we are mixing and matching some parts for the rear tailight.  We didn't finish it during this session (we need to modify a bracket), but we think we've come up with an acceptable way to mount the tailight to the bike.