DO THE TON

Blood Sweat Tears and Grease => Projects => Specials => Topic started by: pidjones on Apr 09, 2018, 18:45:26

Title: the Hunley or, pidjones needed a retirement project
Post by: pidjones on Apr 09, 2018, 18:45:26
Actually, it started back in 2013 when I saw a 1978 GoldWing on Craigslist for a decent price. Basket case? I wish! It would have saved me a lot od disassembly time, and I would have seen a lot more of the ugliness before. So, as new projects go I piled on for a few months. First to be attacked was the carb rack, which seems to be the bane of GL1000 motors. Fund the usual junked-up mess, mud dauber nests, incorrect jets, non-Honda float valves, missing float valve strainers. Having access to a couple ultrasonic cleaners and specialty solvents helped that along. Found a lot of discouraging problems. #1 was that the engine was NOT a '78 (I was planning  on restoration), but a '75! Now, for performance the '75 'wing was the hottest. #2 joy was that the engine had apparently sat under water for a good period of time. This required the right side head to be removed and the #1 and #3 cylinders scraped with single edge razor blades held by hemostats. Cleaned up nice, though. #3 fun item was that the right side head and block were not true. I spent a week on the floor with a single-cut mill file and silicon carbide paper glued to glass to get them true. While weather cooperated I stripped the frame to bare steel, etching primer rattle-can, sanding primer over that, smoothed a few things I'd ground off, and painted it with 4 parts black one part gold, then clear coated. Now, this is  my first time painting with a sprayer. I cheated and used lacquer. It went on real nice, and since  it was to have a loooong time to cure out, should be fine. I hung the frame from the ceiling of the garage. Then life got in the way. Work got busy, family demands, and just plain apathy towards a project that had no pressing need anyway. Then a little over a year ago my boss let me know that I would be given a Reduction In Force at the end of September 2017. The RIF doesn't upset me as I was planning to retire then, anyway - plus they gave me good severance pay and six months of insurance! So in October 2017 I started cleaning (a bit) and re-arranging the garage to return to the project. Next item on the agenda was to check compression now that cylinders were good. #4 chuckle was that the compression test was awful. Pulled both heads and had the valve seats ground and put new valves (and seals) in. Good compression, now. The engine cases were grease and dirt crusted, so I spent about a week cleaning them, then painted them with POR15 engine paint. In between discouragements, I pulled various aluminum covers off to polish. The rear swing arm/drive needed cleaned up and painted I judged. #5 surprise was that BOTH external snap-rings were replaced by internal rings. AND the U-joint was shot, AND the slip-joint although in good shape had the grease seal removed and they had pumped the whole swing arm full of grease. So, eBay to the rescue on the U-joint and grease seal, LOTS of paper towels full of grease to get the swing arm cleaned out, then cleaned and wire brushed the outside for painting with wheel paint. That now sets wrapped up waiting for re-installation (with external snap rings). Oh! Almost forgot another gem! The gas tanked had been "Kreem"ed. What crap that stuff is! They had coated the intake filter screens and only a couple holes were open, so I decided to find a solvent for Kreem. Seems like a big task, right? I did have access to a wide range of solvents. Turns out, Kreem (even well-cured) is fully dissolved in Acetone! I ended up just filling the tank 1/2 full of acetone and turning/swirling it a couple times a day, and it all came out.

So, Why not keep a build thread here? I frequent several GoldWing forums, and have kept up a couple threads on them. BUT, I thought the Hunley might have interest here, too. Can't call it a "cafe racer" - the GL1000 would do well over 120 mph stock.  Not a tracker. certainly not a restoration. A "special"? Sure! BTW, she is named in honor and memory of the brave crews of H.L. Hunley - the first successful military submarine, lost along with her third crew after her only (quite successful) mission during the War of Northern Aggression. She was discovered again in the '90s and raised in about 2002 to be placed in a research facility at the old Navy base in Charleston, SC. Plus, I've spent about 2.5 years under water on submarines myself.

So, I'll try t get some pictures up. Maybe figure out how to use the gallery.
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: pidjones on Apr 09, 2018, 19:22:05
Figured out the gallery and posted up some in-progress pictures from over the past 5 years there.
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: irk miller on Apr 09, 2018, 22:03:29
I love it.  I'm still sitting on a '75 that gets pulled out of the barn now and then. 
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: ridesolo on Apr 16, 2018, 18:28:08
Nice!  Going to enviously follow along.
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: WhyNot on Apr 16, 2018, 19:31:57
Wow, i'm following too.

Title: Re: the Hunley or, pidjones needed a retirement project
Post by: pidjones on Apr 17, 2018, 09:16:51
Well, I'll put most of them in the gallery, but this milestone deserves a post. The frame is now back on the engine (thanks to the wife for helping), and the cooling system hooked up, leak checked, leaks fixed (mainly a small spot on the radiator that I was able to solder), and tank mounted (ask anyone that has had one out and back in - not so easy!)

Starting to come together some.(https://uploads.tapatalk-cdn.com/20180417/0b5828552c798b3f49cd9d62d590552e.jpg)
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: pidjones on Apr 17, 2018, 11:49:03
No high-dollar shop pressing, but a routed oak form, a big aluminum bar, and a BFH does a pretty good job making the fender dimples for the mounting bolts. About 7" was cut off the front of the fender. The chrome will come off and it will be painted dark emerald metallic green along with the front fender, side covers, and shelter sides.
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: CrabsAndCylinders on Apr 17, 2018, 18:28:28
The engine looks great.  These bikes have an interesting frame design.
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: pidjones on Apr 17, 2018, 20:31:31
Took the radiator back off to touch up the paint on the sides. Installed the battery box. Sanded the chrome off of the rear fender and primed with etching primer.
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: pidjones on Apr 23, 2018, 21:31:12
Carbs are mounted, and part of  the electrical hooked  up. Which made me realize that hooking up accelerator and choke cables should be completed before the shelter is mounted for the remainder of the electrical to mount. But, to do the cables I need handlebars to mount them on, and triple tree to mount the handlebars. So, the triple trees are cleaned up for paint which forced me to look closer at the head bearings so they are on order. I removed the old races today. A lot easier than I feared. Rebuilt one of the fork tubes - the other will get done tomorrow. This gets involved, but it keeps me off the streets.
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: pidjones on Apr 26, 2018, 07:18:54
Bearings didn't come, so I hooked up throttle cables, choke, clutch, and tach. Need to mount the shelter to go further on the wiring. Keeping most of the stock harness with renewed connectors. Still need dry weather for more painting.(https://uploads.tapatalk-cdn.com/20180426/0f89d27df3ae1c80b1db326520c562e1.jpg)
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: Maritime on Apr 26, 2018, 09:17:56
Nice, following along, I've been there a couple times on my old girl but not to this level of finish, mines always been, get her fixed to ride, one of these days I'll go this far on her.
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: pidjones on Apr 27, 2018, 10:29:39
Nice, following along, I've been there a couple times on my old girl but not to this level of finish, mines always been, get her fixed to ride, one of these days I'll go this far on her.
If I had only this to ride, it would have been buttoned up five years ago. The 1800 behind it is my DD though, so this work is for "pleasure". And, I'm really enjoying it without time pressure, 'cause I'm slow as mud.(https://uploads.tapatalk-cdn.com/20180427/18e482cdcb140eef43c6e081cc53b530.jpg)
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: Maritime on Apr 27, 2018, 10:53:33
Yep, When I can get another DD that can handle what the 79 does I will then do the slow and steady refurb like you are. May be when I retire for all I know LOL. I just know I'll never sell the ole girl.
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: pidjones on Apr 27, 2018, 22:22:32
I finally was able to paint some! Humidity in the 40's, so I put down etching primer, black (Duplicolor wheel paint), and clear (also Duplicolor wheel) on the upper and lower triple tree and the air filter housing. Also put filler primer on the side panels and sanded them to remove a couple divots. Look like one or two more coats of primer and they will be ready for color. Hooked up the crankcase vent to the air cleaner housing after it was mounted, and then hooked up the drain bottle. A little tricky on a '75 motor (with the kick start quadrant back there) in a '78 frame, but I prefer the '78 system. Hope to be able to shoot color on the tins next week. Kind of wondering if the paint I've chosen will look right over different color primers (olive drab etching primer and light grey filler primer). Might just paint it all with a couple coats of black before I shoot the dark emerald green metallic.
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: pidjones on Apr 28, 2018, 21:37:33
So, hovering Hunley went out into the sunlight today. Also gained triple trees, forks, handlebars, headlight. All wired  up to the point that I was able to get headlights and speedo/tach lights. No indications on the gauge panel, and the starter acts like it is shorted now (it worked a couple months ago for me to do compression tests).
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: pidjones on Apr 30, 2018, 21:57:04
Starter works fine with a fully charged battery! Have signals, headlights, tail and stop lights (no brakes yet, though!) A few more items and I get to see if it will run.
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: pidjones on May 03, 2018, 20:44:02
Painted the tins yesterday. Taking the side covers out to paint I noticed that the primer will still soft. It had been on for a couple weeks at least. I left them aside and painted the shelter sides, radiator scoops, front and rear fenders, and the little piece that bolts to the back of the shelter under the door. Pretty happy with the way the color turned out. It is just lacquer, so I need to let it cure for a bit and then buff the clear coat. A little orange peel in a few places on the shelter sides, otherwise it looks great. Today I scrapped (sanding primer was so soft a lot of it scraped off with a putty knife) the paint off of the side covers and discovered after trial and error that there is a clear coat on the side covers that the primer (which is lacquer-based) doesn't agree with. I have almost all of that off now, too. Tried some etching primer over them lightly and there are just a few spots left to address. I'll get some more etching primer, seal everything off with that, and then lightly apply the sanding primer. Meanwhile, I pulled the rear brake system apart and got one of the pistons out. The side with the connections wasn't so easy (used air to get the first one out). I have blanked the cross port and applied air, but so far no piston movement. I'll get at it again tomorrow. Oh, and recharged the S10 AC system as it will be my work commute transportation on bad-weather days this summer.
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: pidjones on May 09, 2018, 18:24:42
Hmm. Well, I got the other rear brake piston out. Read somewhere the suggestion to hook up the front master cylinder to it and yep, pumped it right out. I've put them both on my lathe and polished - still a few very small pits but these for a '78 rear are made from unobtainium, I think. I have a rebuild kit on hand for both front and rear master cylinders now, plus a rear caliper kit. The front calipers seemed real good when I brought the bike home five years ago. The fluid in them looked pretty good. I'll flush them thoroughly and rebuild the front master.

Rolled her outside today and tried starting. Got a little rumble, but before I could go much further the starter quit again. Guess a charged battery won't do it this time - so I've mounted the wheels and will have the wife help steady the bike while I lift under the center cross member with a floor jack and pull the furniture dolly out from under it. I've already re-mounted the kick stand. Since I haven't mounted mufflers yet it will be easy to drop that header and pull the starter. Yep, um hm. Easy. Well, at least I have all of the wiring finished now - even the horns!
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: Brodie on May 09, 2018, 19:36:23
Projects wouldn't be a challenge without the issues. Pity the battery didn't sort it out. I wonder if the charged battery was just a bit to far gone to give the amps needed to turn the motor around.
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: pidjones on May 09, 2018, 22:14:24
Projects wouldn't be a challenge without the issues. Pity the battery didn't sort it out. I wonder if the charged battery was just a bit to far gone to give the amps needed to turn the motor around.
I wish, but it  is a brand new battery (although I might take it to get tested still). The GL1000 starters have a history with this apparently. There are rebuild instructions and videos, so....  Not a real hard job, just that it has to be on the kickstand to remove/install so the cog stays in the chain and doesn't fall into the motor. I've got the wheels back on it temporarily, and I'll have the wife steady it for me while I jack it up a bit to pull the furniture dolly out from under it. I'm just pumped that I got a few pops out of it! I've never heard it run, and I've owned it for over five years.
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: Maritime on May 10, 2018, 08:17:32
Don't rebuild. the cases warp with use and age and the rebuild has the same issues in a few months. Brand new are available I'll dig out the link. I used one and 10 other members here have, CXman sent me the link when my starter shit the bed on me.
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: Maritime on May 10, 2018, 08:21:34
Here it is, it says 1100 but they are the same for the 1000.

https://www.dbelectrical.com/products/honda-gl-1100-gold-wing-starter-gl1100-80-81-82-83-goldwing.html

Title: Re: the Hunley or, pidjones needed a retirement project
Post by: irk miller on May 10, 2018, 08:48:21
I use the DB Electric starters for the GL and the BMW airheads.  Good products and cheap.
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: pidjones on May 10, 2018, 11:51:27
Thanks, folks! I've saved the link.
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: pidjones on May 10, 2018, 18:23:15
Well, The  starter is out, cleaned up, and back in. Took about an hour once the wife helped me take the bike off the furniture dolly. Left header, shifter, cable, 2 bolts and out. Three screws and apart. One more screw and the brush assembly is free. Commutator looked awful - not identifiable as copper and very pitted. Chucked it in the lathe and spun it with 500 followed by 1200 then 7000 grit using isopropyl as a flushing fluid. Looks nice now. cleaned it up, greased the gearbox (barely had a touch of lithium grease in it) and assembled. Spins nice. Bolted back in and click click from solenoid. Straight shot with a jumper cable and the engine spins right over, so solenoid is on order. Not really surprised. Electrics don't like being under water.
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: Maritime on May 10, 2018, 18:55:21
Good job. And yes solenodes hate wet
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: pidjones on May 17, 2018, 12:58:18
She lives!
Many issues still, but this is the FIRST time that I have heard her run!
https://youtu.be/e0anfmZ95Vk (https://youtu.be/e0anfmZ95Vk)
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: Maritime on May 17, 2018, 16:29:53
Always a great day when the come back to life
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: The Jimbonaut on May 17, 2018, 16:31:22
Alright!  Swear to God, the sound of a bike starting up for the first time is the best sound in the world
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: pidjones on May 18, 2018, 21:54:11
Pulled the tach apart and lubed with silicone spray that I once used on RC helicopters. It is very thin and very slick, and thins other lubricants it mixes with. The tach had been very sluggish and was obviously not indicating correctly. I think I have it fixed now. Pulling that apart was tedious, but putting it back together wasn't that hard. I have to admit that I practiced first on an old speedometer that I have and it was much harder the first time. After testing the tach with my battery drill and remounting it, I mounted up the mufflers that I bought for the bike. I used fiberglass cloth that I doped with high temp copper RTV for the gasket between the muffler and header end. For a clamp I used the clamp that was on the original Honda muffler. Pictures to come after I mount the saddle (which I won't get until next week).
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: Brodie on May 18, 2018, 22:37:14
Rad.
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: pidjones on May 31, 2018, 19:27:36
Got her out and did a quick ride up and down the road. Still way out of tune, doesn't like  to be bogged (most 'wings love it) and the right front brake is dragging bad. Never got  it past 2nd, but shifting was smooth that far (the worst shift on a GW). Brakes were very weak, but starting to bed in already. Worst was the front drag which even makes it hard to move around in the garage, so I'll pull that caliper tomorrow and see if I can free it up. I made sure the return hole was open when I rebuilt the master, and it is just that right caliper. I'm sure there is more carb balancing to do, but I was pretty pleased. It idles well, which is a nice thing.
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: Maritime on May 31, 2018, 20:40:00
Whoot coming along. You'll get her there shortly. Love the green and brown combo. Very nice
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: pidjones on May 31, 2018, 21:16:28
Thanks. Hope your soreness is easing.

Wife snapped me easing out (Yes, I'm an ATGATT believer):
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: Maritime on May 31, 2018, 22:32:15
Thanks. I was atgatt as well. That s why i only have some bruises not broken bits
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: pidjones on Jun 01, 2018, 09:55:48
Thanks. I was atgatt as well. That s why i only have some bruises not broken bits
It sure helps! Two years ago, I had a get-off of my GL1800 at a little under 50 mph in the center lane of 3 in Knoxville on I-40. Lots of soreness and destroyed my gear (insurance replaced it all with new), but I only had a cracked wrist process. No blood, EMS and ER were amazed.
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: Maritime on Jun 01, 2018, 10:23:32
I remember reading that. If it wasn't for the deer being pinned between bike I would have only had a broken pinky finger and some bruises when I got hit. damn animal had to go and crush my lower leg, although I got higher better boots since just in case LOL.
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: pidjones on Jun 07, 2018, 22:56:30
Painted shelter and side covers today (Duplicolor Dark Emerald Green Metallic). Side covers came out good, a little orange peal that I hope will sand out. Shelter covers developed bad boogers. Must have been a bit of enamel that I had sanded through the primer to. It will probably all have to come off and be redone. Might just rattle-can them with black lacquer for the summer. This may have been the last low humidity day until fall. Parts for upper brake line were shipped today. Not planning to ride it anymore until the front brakes work. So far a grand total of 2.5 miles!
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: Maritime on Jun 08, 2018, 08:20:15
Too bad on the booger paint, I hate that, I painted mine 3 f'n times because I used the wrong painters tape.  It can be fun getting the front brakes right. I upgraded to a mid 90's CBR master and braided lines, after that they bled and work much better than before.
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: pidjones on Jun 08, 2018, 18:44:18
Really not happy with the shelter paint. The lower side covers should be OK once polished out, but the lacquer is too soft still for that. I just hung one side on to take a photo. The shelter covers on both sides have artifacts that I believe are from underlying enamel that was exposed by sanding through the primer (that somehow avoids messing up the enamel even though the primer is lacquer-based). Plans are presently to not sand all of the paint off, but rather scuff it and hit it with etching primer once it hardens, then color. I think I'll wait longer between color coats - maybe I rushed it this time. I'll let the color set, sand out the orange peal, then do the clear coat with greater time between coats on it, too. I love the color and it worked great on the fenders that were sanded-down chrome and steel. I'm sure it was the original Honda enamel that is fighting me. I had to sand off or completely cover with etching primer for the lower sides.
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: The Jimbonaut on Jun 08, 2018, 20:48:55
Damn though, that green.  Looks absolutely fantastic, and by the sounds of it will only get better.  Great job.
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: Brodie on Jun 08, 2018, 21:45:36
Looks good man. Pity about the surface finish.
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: pidjones on Jun 10, 2018, 17:59:18
This afternoon I finished bleeding the front brakes (necessary after replacing the upper front brake line). I installed a new boot on the right front caliper piston. The I pulled the speedometer and opened it so that I could lubricate the pointer shaft with some very thin silicone oil, thinning and flushing the thickened stuff that was in it. Then re-sealed and installed the speedometer. I think it is safe to start taking longer rides on it, if the weather will cooperate!
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: pidjones on Jun 14, 2018, 17:00:35
This morning I backed her out of the garage, warmed her while donning gear, and took her for a 6.4 mile loop through the valley. Yowsa, I don't remember this kind of kick from my '77 GL1000. Once she passes about 3500 RPM, I must be hanging onto the grips with BOTH hands! The bump at the back of the seat came in handy! Feels like it weighs much less than my '77 did. Although she is still a bit rough at lower RPM, man was she nice when wound out. Even managed to get her through all 5 gears, but never fast enough for 5th (or even 4th) to feel that happy. Tires are 13 years old and I can feel how hard the rear is when using the rear brake. The front is much better, but may still need another bleed. Won't be riding her more until July 12th, when the insurance on her starts (changing to Dairyland along with my GL1800) - bu-bye again, Flo!

You may have noticed in previous photos the paper towels taped around my grips (NOS Kury Isogrips). I needed a better solution (for keeping them clean) for that, so.... cheap, easy on-and-off, but hard to find non-lubricated - condoms.
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: pidjones on Jun 16, 2018, 19:58:44
Pretty hot out today. I did get out and mount the Hunley onto the trailer I built for her out of Harbor Freight frame and loading ramps. Rode it right up. The trailer has fold-down side boards because I've seen way too many YouTube videos of guys dumping their bikes loading or unloading them. Still not happy with the strapping down plan I had. The ratchet straps I bought at Harbor Freight are crap - jambing every time. The high-strength cam buckle straps slip at every opportunity. I'm going to Tractor Supply for some SmartStraps. These seem like the best I've ever used.
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: Maritime on Jun 18, 2018, 08:35:36
Nice!
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: JustinLonghorn on Jun 19, 2018, 10:24:03
I can dig it.
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: pidjones on Jun 22, 2018, 20:06:34
The weather has really been poor for riding - either steamy 90's or raining or wet roads. I am not about to take these 13 year-old hard tires on wet roads. So, I've been finishing up the trailer I'll haul it to shows on. Loaded her up and did a couple mile loop around tight turns, railroad tracks, etc. Seems to ride fine.
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: pidjones on Jul 07, 2018, 23:06:03
Put about 40 miles on her today before it got too hot and the thunderstorms rolled in. Rode over Norris Dam and back. She ran fine. Still need front brake improvement, and tires! Still, she feels very confident in turns.  Need to find out how to adjust the damping of these Progressive rear shocks. Riding almost like a hard tail. I back off the spring load, but I don't think it will soften the ride any. I might just be spoiled by the GL1800 (which is much heavier) ride.
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: pidjones on Jul 12, 2018, 09:04:05
The right side is still much louder than the left, and I think I've figured out why! Back in 2013, when I first started work on it, I had to file on the right side head and block both to get them flat. I don't know how much I removed but it may have been as much as 5 thou (total). Could this have increased the compression on that side? I know that my compression testing a while back showed #1 to be 20 psi higher than the other cylinders.
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: Maritime on Jul 12, 2018, 09:11:19
Could be, these motors have high compression to begin with, When I did my gaskets and tested after, the bike had the high side of factory spec and it has 200K+ miles on it, so I bet you could have increased it.
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: pidjones on Jul 14, 2018, 19:56:20
Loaded up the Hunley and took it to Stearns, Kentucky to the Moonshiner's Run Car Show. Had a great time, met some wonderful folks, and talked to a lot of them about the Hunley. Next up is new lower brake lines and new tires, so I can get some riding in this fall!
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: pidjones on Jul 31, 2018, 06:49:52
Back on the furniture dolly. Wheels are at Honda of Knoxville for mounting the new Duro 918s. I know Shinkos are popular for this, but I had bad blistering on my GL1800 with them.(https://uploads.tapatalk-cdn.com/20180731/3a8a2cd4fcfc6bb529f8e5f67e7ee855.jpg)
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: pidjones on Aug 02, 2018, 17:55:45
Well, the wheels and new tires are on and the new lower brake lines also. Bleeding the front brakes I noticed fluid on the plastic that I had put over the shelter (glad I did). Coming from the master cylinder around the push rod. Went ahead and ordered a new China el-cheapo and it is on the slow boat (uh, I mean China Post). So, with things a bit on hold and monsoons rolling through the rain forests of East Tennessee, I decided to check on engine things. Ohmed plug wires #1 to #2 is 25.2 kOhms and #3 to #4 is 25.8 kOhms. # 2 plug looks awful - I don't see how it could fire there is so much wet black (gas smelling) on it.

I then did a (cold) compression test which was really confusing.

Remember now, #1 and 3 cylinders had been discovered with bad rust that I scraped off with razor blades. #2 and 4 looked fairly good. #1 and 3 first compression tests were bad and #2 and 4 were Ok. Well, NOW #1 and 3 are 180 psi! BUT!!!! #2 and 4 are down to 120!!!???

So, I am suspecting (hoping) that I've missed a tooth on the left cam belt. Would explain a lot of things like fuel economy, difficulty in getting it timed, difficulty in balancing carbs. Oh, replaced the carb 2-4 balance screw today as the old one seemed maybe stripped.

So, left belt cover comes off tomorrow and (hopefully) correct that issue, then redo static time, valve lash, fire it up and do strobe timing followed by carb balance. Don't mind that work - a lot better than thinking about one bank running 60 psi lower than the other.
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: Maritime on Aug 03, 2018, 08:24:09
Check valves on that side too, may have gotten tighter.
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: pidjones on Aug 03, 2018, 14:37:45
Well, I'm happy. :) Removed the left belt cover (ratchet head wrenches are a blessing) and indeed the belt was off by one tooth. Corrected that and readjusted left side valves. #2 and #4 compression is now 155 and 175 psi! After a bite of lunch (wife is cooking catfish), I will reset static time, put the clear timing hole plug in, and take her outside for strobe timing and carb re-balancing. Woho! Maybe she will be too loud out both sides now!
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: Maritime on Aug 03, 2018, 14:54:09
Woot there you go. Good luck with the time and sync, should run much better after that.
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: pidjones on Aug 03, 2018, 21:40:21
We have much better idle and throttle response now. Retimed (static - checked with strobe and was spot-on) and balanced carbs. Made some spools out of some scrap aluminum slugs I had and tried out the Harbor Freight stand I'd picked up a few months ago. Makes it muck nicer for working on. The spools are mounted to longer lower shock bolts. I have allen heads on order that I'll counter sink into the spools.(https://uploads.tapatalk-cdn.com/20180804/3bdf4066e6056b27acee8c5a55ec8df5.jpg)

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Title: Re: the Hunley or, pidjones needed a retirement project
Post by: pidjones on Aug 06, 2018, 21:03:35
Bled the front brakes still again, and have a pretty good lever now. Pulled the lift spools I had made off and counter-bored them for the new grade 12 (all that was available) Allen head bolts and washers and re-installed. Now I can pick it up easily with my spool lift. Makes work on it much easier, and storing it on the stand keeps it upright so the left bank doesn't fog the neighborhood on startup (I had ground off the center stand).
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: pidjones on Aug 19, 2018, 17:12:29
Shazbot! Took her out for a Sunday ride. Started blowing headlight fuses, so headed back home after only 20 miles. Coming down our steep, concrete, tree shaded drive, all traction decided to leave and I stuck her in the woods near the bottom. Pulled her out with the winch on the wife's mule and soft straps. Looks like I get to touch up the barbeque paint on the headers and re-polish the right valve cover and belt cover. And, find the short in the headlight circuit. I  suspected no headlight when I saw the voltage about .5 higher than normal.(https://uploads.tapatalk-cdn.com/20180819/4f9c600e62567bf97cafd44db8de577a.jpg)(https://uploads.tapatalk-cdn.com/20180819/e9f7ebd7f21b71178293b233a65c1009.jpg)(https://uploads.tapatalk-cdn.com/20180819/d8374039bac2ec30b7efd20dbce4543b.jpg)(https://uploads.tapatalk-cdn.com/20180819/1f62d94a9ae8a2020a533343521233de.jpg)
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: pidjones on Aug 19, 2018, 17:16:05
This green mold is SLICK!(https://uploads.tapatalk-cdn.com/20180819/a35c295eed47854c944d8de38e2ac0a2.jpg)
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: Maritime on Aug 19, 2018, 17:58:37
Ouch. Glad you're ok. I did similar on the wet grass on side of my drive.
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: ridesolo on Aug 19, 2018, 22:05:50
Dang, really sorry to see that!  Glad you are ok, though, bikes fix easier than people.  The wooden ramp at the back of my shop is on the north side of the building and doesn't get any sun.  I found out the hard way that it gets very slick when wet.  I went down hard one day and the Mrs. almost had to call the squad.
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: pidjones on Aug 19, 2018, 22:19:42
Thanks, guys. I wasn't hurt at all, and after looking her over close (and hosing her off) I think that all that will be needed is a touch-up of  the exhaust headers. I'll just shove some cardboard behind them and mask off the engine parts. Luckily I wasn't pre-crunched like Maritime. I may have a sore butt cheek in the morning, but not feeling any ill effects now. Think I  may pick up a bag of play sand at Lowe's on my way back from getting new tires  put on the daughter's car tomorrow. I slid about 3/4 of the way down the drive, amazed that I kept her up as long as I did and probably only fully lost her when the front wheel got off the road. The scrapes on the concrete appear to be from the footpeg slider and the headers. VERY little abrasion to the valve cover (that already had marks from a previous owner).
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: CrabsAndCylinders on Aug 19, 2018, 23:45:25
Crap, I hate when that happens.  Glad it wasn't too serious,
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: pidjones on Aug 30, 2018, 06:41:50
Working the big crowd at WingDing 40 in Knoxville. I was honored to put the Hunley (far back right) in Pistol Pete's display of GL1000s. This group includes serial # GL100000002 - the oldest in America, along with 40 and 104. Also a supercharged '75 and several others. He wanted the Hunley as an example of how bad they can be and still be rescued.(https://uploads.tapatalk-cdn.com/20180830/3eb593858a7a6efde52c374eab5fda1b.jpg)
Title: Re: the Hunley or, pidjones needed a retirement project
Post by: Maritime on Aug 30, 2018, 08:49:19
Rad, that's great.