1972 Jawa 250 Californian - Rust Machine
- Thread starter damiansd
- Start date
damiansd
Been Around the Block
My current task is getting the crankshaft out of the case. I've got my jig all made up but she doesn't want to move.
Here is my jig.
On one occasion I broke a bolt and had to use my new screw extractor (easy out) to get it out. Then the two screws below got threaded.
Must be time to go and find a high-tensile bolt that can cope with what I'm asking it to do. A bit of heat will be applied next time too.
Totally frustrated, I decided to change tack and break down the front fender. There you go, much more satisfying. Don't see a front facing number plate much these days (Thankfully).
Cheers,
Damian.
Here is my jig.
On one occasion I broke a bolt and had to use my new screw extractor (easy out) to get it out. Then the two screws below got threaded.
Must be time to go and find a high-tensile bolt that can cope with what I'm asking it to do. A bit of heat will be applied next time too.
Totally frustrated, I decided to change tack and break down the front fender. There you go, much more satisfying. Don't see a front facing number plate much these days (Thankfully).
Cheers,
Damian.
damiansd said:My current task is getting the crankshaft out of the case. I've got my jig all made up but she doesn't want to move.
Here is my jig.
If you can It would be a good idea to replace that center bolt with something of a larger diameter and finer thread, That one if its really tight would strip out before moving the crank.
Interesting to see a jawa being worked on, whats the parts availability like?
damiansd
Been Around the Block
Hey notlob,
Yeah, you're right. A bigger bolt and nut!
Parts for the Jawa aren't too terrible, if you are ok with ordering from the Czech republic and the UK. I have a local supplier who has a bunch of parts so that's helpful too. Slim pickings on the local ebay though.
It's funny looking through all the builds on here, Honda Honda Suzi Kwaka Honda.... then this weird old Czech thing shows up.
D.
Yeah, you're right. A bigger bolt and nut!
Parts for the Jawa aren't too terrible, if you are ok with ordering from the Czech republic and the UK. I have a local supplier who has a bunch of parts so that's helpful too. Slim pickings on the local ebay though.
It's funny looking through all the builds on here, Honda Honda Suzi Kwaka Honda.... then this weird old Czech thing shows up.
D.
damiansd
Been Around the Block
Today I got the rear fender all disassembled. The little bolts just wanted to spin so the grinder came out to play.
The tail light and indicators are still in nice condition and should come up great.
Next up was a look at the tank. I assumed that the inside was full of rust. If that was the case I planned to fill it full of nuts and bolts, wrap it in a blanket and throw it in the dryer. I even went through the discussing the abuse of the dryer with my wife. She was cool with it too.
But, I didn't need to. A quick look inside the tank and it was pristine. I nearly fell over. No rust, just shiny silver sides. That's one chore I won't have to do.
The cylinder gets dropped off this weekend for a rebore, so I'll continue with the prettying up for now. Handlebars are next.
Cheers,
Damian.
The tail light and indicators are still in nice condition and should come up great.
Next up was a look at the tank. I assumed that the inside was full of rust. If that was the case I planned to fill it full of nuts and bolts, wrap it in a blanket and throw it in the dryer. I even went through the discussing the abuse of the dryer with my wife. She was cool with it too.
But, I didn't need to. A quick look inside the tank and it was pristine. I nearly fell over. No rust, just shiny silver sides. That's one chore I won't have to do.
The cylinder gets dropped off this weekend for a rebore, so I'll continue with the prettying up for now. Handlebars are next.
Cheers,
Damian.
damiansd
Been Around the Block
Handlebars all dismantled. Cylinder sent off to get rebored.
In the meantime, preparations for painting begin.
The plan is:
That's the plan. Let's see how it pans out.
D.
In the meantime, preparations for painting begin.
The plan is:
- Truck wash fenders, side panels, tank and frame to remove as much dirt and runge as I can
- Get the paint stripper out, slacker it on thick then scrape off and power wash as much as possible
- Fill a metal garbage bin with 1 part mollasses and 9 parts water, put the parts in (besides the frame)
- Let it all soak for a fortnight then power wash it all
- Get the wire wheel onto any stubborn pits
That's the plan. Let's see how it pans out.
D.
damiansd
Been Around the Block
The kids wanted more to do. So I've got them cleaning parts pre-painting.
Today's job - covering all parts in truck wash, letting it sit overnight, then attack it with the power washer.
Here it is soaking in truck wash as at last night.
Tonight, the power washer war begins. Yeah, they'll all get wet. Yeah, they'll make a mess in the house when they come in. But at least they'll have fun.
Cheers,
D.
Today's job - covering all parts in truck wash, letting it sit overnight, then attack it with the power washer.
Here it is soaking in truck wash as at last night.
Tonight, the power washer war begins. Yeah, they'll all get wet. Yeah, they'll make a mess in the house when they come in. But at least they'll have fun.
Cheers,
D.
damiansd
Been Around the Block
The power washer did well. Probably need another go on some of it. At least it's all straight and no extra holes.
The paint is chipping on some items, showing a lovely rust colour underneath. Molasses will deal with that. But first the kids have another job.
Bring on the paint stripper!
For giggles I have the exhausts soaking in truck wash. I know that they won't be happy, even after a power wash. But let's see eh.
Damian.
The paint is chipping on some items, showing a lovely rust colour underneath. Molasses will deal with that. But first the kids have another job.
Bring on the paint stripper!
For giggles I have the exhausts soaking in truck wash. I know that they won't be happy, even after a power wash. But let's see eh.
Damian.
damiansd
Been Around the Block
I bought a spray can of paint stripper. And it was pathetic!!! Didn't do a thing. I've asked my wife to take it back tomorrow for a refund.
So, disillusioned, I started on the wiring loom.
First impressions - it's a total rat's nest. It looks like every piece has been hacked at some point. I put some voltage across the horn and it made a weird little noise. OK, that has to be swapped out.
The switch block was a corroded mess, inside and out.
I decided to throw the switch block at the wire wheel, to see how it would come up. Half way and not bad.
And here it is finished.
Houston, we have a problem. That is not a Jawa switch block. Skullduggery!!
Aint none of that Yamaha stuff infiltrating this build. Besides, it almost dissolved in my hand. The switch block will get replaced with something else, not sure what.
D.
So, disillusioned, I started on the wiring loom.
First impressions - it's a total rat's nest. It looks like every piece has been hacked at some point. I put some voltage across the horn and it made a weird little noise. OK, that has to be swapped out.
The switch block was a corroded mess, inside and out.
I decided to throw the switch block at the wire wheel, to see how it would come up. Half way and not bad.
And here it is finished.
Houston, we have a problem. That is not a Jawa switch block. Skullduggery!!
Aint none of that Yamaha stuff infiltrating this build. Besides, it almost dissolved in my hand. The switch block will get replaced with something else, not sure what.
D.
AgentX
Over 1,000 Posts
damiansd said:
You might check with jainenfield.com , bulletwala.com, or Chawla Auto spares in Delhi--they're all Enfield specialists but probably have a line on other parts. Of course, shipping from the US or the UK is going to be a lot cheaper, more reliable, and less prone to customs problems, but I thought I'd toss it out there for you.
My last big ride in India, we passed an old guy on a gorgeous emerald-green Yezdi out on the highway, in full white robes and carrying his cane. Pretty good visual take-away.
Google gave me this resource, too:
http://groups.yahoo.com/neo/groups/yezdi/conversations/topics/40061
damiansd
Been Around the Block
Continued the power tear down.
I decided it was time to see what the internals of the headlight looked like. Before I get into that, the silver lining in the headlight bucket is peeling away. I'll need to sort that when the time comes.
OK, here is the rats nest of wires once I opened the bucket. Lots of non-standard, flakey stuff in here. Surprised it didn't go up in flames last time it ran, whenever that was...
Snip snip snip and things look a little cleaner.
The old loom that I'll be rebuilding from scratch. I've got some electrical background so I'm not too intimidated by this piece.
The rat has been evicted. Much neater. For now.
D.
I decided it was time to see what the internals of the headlight looked like. Before I get into that, the silver lining in the headlight bucket is peeling away. I'll need to sort that when the time comes.
OK, here is the rats nest of wires once I opened the bucket. Lots of non-standard, flakey stuff in here. Surprised it didn't go up in flames last time it ran, whenever that was...
Snip snip snip and things look a little cleaner.
The old loom that I'll be rebuilding from scratch. I've got some electrical background so I'm not too intimidated by this piece.
The rat has been evicted. Much neater. For now.
D.
damiansd
Been Around the Block
Paint stripping take #2.
This time the paint stripper is a bit stronger. Not just dirty water this time.
In progress.
How it came out after much scraping.
It well need another go. As much as I'm impatient to get to paint, I want this prep done right.
Cheers,
Damian.
This time the paint stripper is a bit stronger. Not just dirty water this time.
In progress.
How it came out after much scraping.
It well need another go. As much as I'm impatient to get to paint, I want this prep done right.
Cheers,
Damian.
damiansd
Been Around the Block
Finally got the swingarm removed from the frame. Local bearing place ended up using their 10 ton press to get the sleeve out. I'll revisit them when it is time to press it back in. Now the paint removal, clean and repaint can begin in earnest.
Son #3 stripping the paint off the swingarm.
Not bad boy, not bad.
Daughter is busy hitting all the parts on the wire wheel after the paint stripper has done it's thing.
Bet you can't tell she likes making things shiny...
D.
Son #3 stripping the paint off the swingarm.
Not bad boy, not bad.
Daughter is busy hitting all the parts on the wire wheel after the paint stripper has done it's thing.
Bet you can't tell she likes making things shiny...
D.
