Alright everybody, there has been some progress. I apologize for the delay but with the holidays and being out of town, my work schedule has taken a backseat for a few weeks. I have yet to document the aftermath of the teardown of the frame but here is what has been done with the motor. I sent it out to a man in TX that does vintage motorcycles (more specifically Hummers) for a living to do the rebuild. He documents the whole process and sends it back to the customer and now I am going to share the rebuild with you all.
This is when he opened the crate that we built to ship the motor in. Looking pretty sad..
Unfortunately our packing job was not sufficient and we had a damaged fin. No worries for Charlie but it would end up costing us a pretty penny to fix it.
Cracked open the motor. The piston in it in this photo was a .040 but it needed to be bored (obviously)
Here it is being bored to .050
This motor had an early rod with a 1/2 inch brass bushing (not good for longevity) and wrist pin. The factory never made a .050 piston to fit the original rod but since it was shot anyway he used a rod from a 1951 and newer motor with needle bearings and a larger wrist pin and crank pin. He said he didn't think the bottom end had ever been torn apart but that the owner kept rebuilding the top end. I think this bike used to be used as a makeshift "hillclimber" based on the tires and size of the sprocket.
The flywheel being disassembled. The rod, rollers and crank pin were way out of spec.
Here is a shot of how bad the rod sags.
Two teeth were missing on the kicker gear.
Charlie welded and reshaped it into working order.
Here is the flywheel rebuild and reassembled. It is being trued on his special truing stand.
This is the transmission disassembled, blasted, and cleaned.
Transmission reinstalled into the blasted case half.
Crankshaft main bearings and flywheel installed into the left case.
All of the seal housings were refinished and new seals installed. Cases assembled and sealed.
New sprocket installed (he said the original was the most worn he had ever seen). Armature also installed.
He rebuilt the generator. Here it is reinstalled.
Sidecovers refinished and installed.
This is the new .050 piston assembly, studs, hardware, and head/base gaskets.
Piston assembly installed. He even replated the dipstick in this photo
Cylinder installed and motor being timed with a dial caliper and an ohm meter for true accuracy.
Starter assembly reinstalled with the completed kicker gear.
Clutch basket and new primary chain installed.
Completed assembly. Notice the fixed fin.
View from the other side.
Here is the motor as it would be shipped. Charlie hooked me up with a completely restored carb and throttle cable as well as the correct spec spark plug.
I will try and get some shots up of the disassembled bike. It will go out to powder hopefully sometime this week!
