Therapy 2

[WJP]

Having sorted out Therapy earlier this year and as a treat to myself following completion of my own therapy I decided to take on another project during my chemo recovery before I start work again in the spring.



This project doubled in size a few weeks ago.
I missed out on the Can Am that Moose was selling and so during the summer I bought this lot in a field, as you do!




In principle there are all the bits needed to make an engine, it says 97mm on the piston so its a 604, not the 500 it was thought to be. and I will have some spare bits of a 350 left over.

Then a few weeks ago I got chance of another project bike in need of some TLC.



I have now sorted out the electrical, fuel, brake, rear shocks and drive issues and last week got it an MOT

So the winter project will be to put the 500e into this frame to make a light weight off road, build the 604 engine and put that in the current bike and fully fit it out with panniers etc for road biased work.

My plan is to build these, check out they work and make any modifications/weld etc and then depending on time strip back the 604-Road and do a proper powder coat and plastics paint job.

So progress to date is that the engine parts have been taken apart under the watchful eye and guidance of Minter. Sent for blasting and powder coating. I collected the parts earlier this week



Just started to clean up all the threads etc to make sure there is no blast media left behind.




When not in Minters surgery on the 604 rebuild, I have made a start taking the bikes apart and appear to have made a nice low rider, for my 7yr old nephew to sit on at Christmas!



So my priority is to sort out the 500e off roader first, build the 604 and then install and sort out the road bike

So that should keep me busy and help me get back into the swing of things.

[Thumper]

Bloody hell. That will keep you busy...

What a great set of projects!

[gegdonnell]

How do you find the time for these projects.

[mt bandit]

good on you mate,
it truly is a labour of love, as i'm finding out,

[jamba]

Looks soo nice those clean parts

[twmtomos1]

looking good keep up the good work

[appyarry]

I must be looking in the wrong places, Oxon must be a better hunting ground than SE Kent

They will look nice and I like the magnolia one as well

[Flying Dutchman]

Are these pictures from the original Harley-Davidson factory productionline?

[WJP]

Are these pictures from the original Harley-Davidson factory productionline?

It sometimes feels like it, I have two more in Toronto
you haven't seen the engine storage area
thats why the latest engine to arrive is for sale

[WJP]

I thought it was time to provide a bit of an update. I had a great Christmas, helped by the fact that having finished Chemo I can now eat and drink whatever I want, so I did.
I didn't get any garage time with the various family commitments away from home and friends for new years. So this week I got stuck in as I wanted to make progress and see if I could do a full day without having to sleep in the afternoon! - I can so I must be getting better.

Luckily, I have been in the heated garage working on the off roader by day and at Minters on the 604 in the evenings. So this is whats been happening over the last few days....


Phase 1 of the off roader is now finished, its got a 500e and a refurbished Amal driving a 15/47 ratio. Rear shocks are from a 500 so think it will be a bit softer. Exhaust de rusted and painted, handle bars put back to standard type spec, as upon closer inspection the original renthals that came with the bike were bent/cracked, and then added some plastic hand guards. New Michelin AC10's are on order to finish this particular project. All the other heavier hardware, pannier mounts, rear stays etc will be boxed up so that the bike can be put into normal spec if ever I decide to sell it.

The only outstanding thing to do now is to get outside and sort out the carb setup as all that fresh paint on the exhaust will be setting too many smoke alarms off if I do it inside! Play around with the set up as I think it needs a bit more pre load on the shocks. So I get to ride again!

I have decided to stop at that point with this bike for now, phase 2 if it goes ahead, will be to put on a front cowl that I have from a ccm with digital speedo and some new rear plastics, but that can wait until I know how the bike rides.

New bits from Amal and the old vs new 2A1 needle, its got to be better!

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Putting it all back together and re routing the front brake line resulted in the need to bleed hence the zip tie overnight - no problems

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So the road project has got underway, the bike is almost stripped down and should be going for blasting and powder coating next week. This will be receiving the 604 that is now starting to take shape.

Lots of prep work to clean up all the powder coated parts but I am sure it will be worth the effort. Pictures below show progress made last night as we started to assemble the bits. The oven ready cases received frozen new main bearings and seals. This was followed by a bit of crank pulling, gear box jiggling, finished of with some glue and torquing . I made the coffee while Gary was jiggling!

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I have to say this is so much better than sitting around watching day time TV and feeling @#$%. All being well I will be working again soon, so better get on and finish these bikes as I don't think I will have as much time in the garage when that happens.

Many thanks to Gary for all the help and banter

Cheers
Will