Archive for August, 2012

I have been keeping the momentum going with the ‘65 Revive project. After I previously tore down the 2 engines and determined just how much was going to be required to bring the power plant to life I started to create a plan. So I spent some time cleaning all of the engine internals in order to be able to perform a more accurate, and final, inspection of everything. There is way too much for me to list, or talk about, with all the intricate details involved in the rebuild. Let’s face it pictures are way more fun. So the details of this post are going to be outlined in the following shots.

Second gear on the countershaft had a broken tooth however I was able to swap a good gear over from my spare gear box. All other transmission components inspect good. I am planning to press on a couple of new bearings and I am currently in the process of trying to source the bearings. I think I found a couple of winners today.

The charging system windings measured out good with no opens or shorts and the resistance specs look right. Some of the wire lead insulation suffered some cracking due to age and heat however I was able to seal things up with liquid brush on electrical tape.

The oil pump system all inspects good. Intake and outlet valves are great and the pickup screen is in decent shape. The o-ring on the oil filter cap was corroded on but with a bit of heat things came apart. Cleaned up all the surfaces on the lathe.

CLutch is in fantastic shape. I was convinced that a set of clutch frictions and plates would make its way onto my parts list however everthing measures out great. Friction thickness is perfect and all the steels have no warpage or signs of excessive wear.

The camshaft and rocker arms from the original engine were shot showing lots of wear. Luckily the spare engine cam, and valve train, inspect to be in great shape. They are a keeper!

Between the original engine and the spare engine I have 2 complete sets of valves, springs, and related hardware. The exhaust valves can be saved however all the intake valves are pounded out. New will be required.

I was fortunate enough to be able to end up with a complete set of good condition side covers. Clean up and powder coating will make them look great.

The cylinder head from the original blown up engine will need to be used as the spare engine head had broken fins. The heads combustion chamber will need some love however it should be salvagable. The barrels cleaned up great however their destiny will be unknown until it goes to the machinist.

The cases from the original and spare engines were all garbage. I was able to pick up this used case which inspects to be in great shape.

Initially I was going to get rid of the electric starter and just rely on the kick starter however I have changed my mind. Due to control logistics the kick starter may interfere with the rear sets therefore the starter is now back in the game. All the starter components inspect great, including the brushes, so it will get a clean up and reassembly.

Carbs have been sitting for awhile, lots of debris in the float bowls however the rest look to be in good shape. A couple of carb rebuild kits and a good soaking in carb clean should fix them up.

The crank out of the spare engine measures up good. Lateral play in the connecting rods measure good as well as the axial and radial play in the bearings are within spec.

Got my hands on a couple of Keyster carb kits so both carbs recieved a complete overhaul and reassembly, everything is working smooth.

Sourced out the ignition components which consist of a Dyna coil and wires, factory Honda plugs, as well as NGK resistance plug boots.

Found a set of NOS outer valve springs as well as a couple of NOS intake valves to replace the old pounded out ones.

Gaskets galore. Was able to round up all the gaskets, seals, o-rings, and Hondabond to make sure things remain leak free.

NOS triple oversized pistons and rings. Decided to replace the wrist pins and circlips while I was at it.

I took the time to start performing some work on the CB160 65 Revive project. The plan right from the beginning was to first address the power train aspect of the project. Since the bike was purchased with a blown up engine it was important to establish whether or not the engine could be saved and therefore continue on with the remaining components of the bike. When I bought the bike a spare engine, of unknown condition, was included. The spare engine had external signs of issues most notably being the broken cooling fins on the cylinder head.

So I started by first tearing down the spare engine and laying out all the parts. Next the original blown up engine was removed from the bike and it too was torn down. Once I had every single component from both engines disassembled and laid out I was able to start performing a thorough inspection to determine what I was dealing with.

Well it turned out that there was a significant amount of damage found in both engines. Both the original engine case and the spare engine case had holes in them. Transmission teeth were broken, piston ring lands broken, clutch rods bent, cases welded, plus multiple other issues. So I am turning this post into a picture post with captions. I took pictures of the significant issues and documented them. I have yet to clean everything up and do a final inspection however at this point, even with the known damage, I am feeling good about being able to save the power plant. It’ll take some time to source parts however I think the challenge is realistic. So you can join me below in observing the reality of what I am forced to face.

This is just one of the benches that the engine was laid out on. The parts viewed heare are all from the spare engine. The second bench was comprise of a couple of saw horses and and an old door that is suspended overtop of the bike in the middle of the shop.

The spare engine had multiple welds on it. Based on the condition of other external components I suspect this engine was involved in an accident. This particular weld was on the bottom side of the lower case. The mount that is shown is for the foot pegs.

These are the cylinders off the origianl engine. Obvious damage is visible and the barrels have been completely destroyed.

This is the cylinder head off the spare engine. The internals of the head are in decent condition however many of the cooling fins have been broken. So as far as the casting goes it is garbage however some of the internals may be salvaged.

This is the upper case half of the original engine. The case got a hole punched through it when the engine blew up.

The rocker arms of the original engine had lots of wear on them. The picture does not illustrate this very well however all 4 arms are good for scrap metal now.

Second gear on the countershaft of the spare engine had a tooth missing. I found the “loose tooth” in the bottom of the case.

I was really hoping the pistons in the spare engine were going to be good. No luck. One of the pistons had broken ring lands. The donor engine had already been bored out 2 sizes over as it had .50 pistons in it.

The valve cover/upper engine mount of the donor engine was repaired with a substance similiar to JB Weld. Although the picture doesn’t show it the underside of the cover has a clearly visible break in it. More eveidence that this engine was involved in an unfortunate incident.

Major cam lobe wear in the original engine. The wear matches all the wear on the rocker arms.

This is the clutch actuation rod from the donor engine. It was clearly bent. I am unsure exactly how something like this would happen, it is possible that the damage may be related to an accident.

Here is the crankshaft, rod, and piston assembly out of the original engine. There were no sign of a piston when the cylinder head and barrels were removed. The nub of the broken rod is what punched through the upper engine case and cylinder. Based on the cam wear and the broken rod I am suspecting the engine may have suffered from oil starvation.

This is what remains of the pstion, wrist pin, and oil seperators from the original engine. This was all collected out of the bottom of the engine case after it made its way through the transmission.

This is the bottom half of the engine case from the donor engine. There was a hole punched throught the bottom. Based on the break it was obvious that it was a result of external damage. That makes for 2 bad engine cases.

I got sidetracked on a project a couple months ago. It was taken on as a result of pity I felt towards perfectly good piece of equipment. I have access to a scrap metal pile and the other day as I peered into the kingdom of metal awaiting reincarnation I spotted an old floor jack. The jack was a typical 3300 lbs capacity automotive floor type, nothing special and certainly not really worth anything however it seemed a shame to throw out something that, with a bit of love, could be given a 2nd chance on life.

So I dragged it out from the middle of the pile and was lucky enough to find the handle that belonged to it. Upon close inspection it appeared that the hydraulic portion wasn’t working however the frame looked straight and all the components looked to be in decent shape.

So I decided to see if I could breathe some life into it before I sent it to rehab. I topped the ram up with fresh hydraulic fluid, bled out the pump, slid it under a car and was able to extend the ram to full height no apparent issues. There were no obvious signs of leaks so I was a bit puzzled as to where all the fluid had previously disappeared to. Perhaps someone left the bleed screw loosened off at some point in time. Anyway…the jack appeared to want to remain in service so I figured a complete tear down, inspection, and rebuild was in order.

So the surgery began with a full disassembly. All the pump seals were inspected and determined to still be in a useable state. The ram piston was polished and all hydraulic internals were cleaned. The idea was to rebuild the jack completely custom with the challenge of putting no money into it. Any part, or supply, that was needed would have to either be build from scratch or be something that I already own.

With the workhorse portion of the jack verified to be good it was then a matter of cleaning, prepping, finishing, and reassembling the complete unit. So over the past couple months when I had time in between my in between projects (yes that’s 2 in betweens) I sandblasted, polished, and powder coated the jack using a combination of Safety Orange and Flat Black powder coating. All the small hardware including the ram powder was all polished.

The caster axles were pressed in and peened into place so they required drilling for removal. A new set of axles were machined out of a couple of 10mm bolts I had laying around. The jack handle grip was in poor shape and had the end torn off so I decided to machine an aluminum one and polish it in order to help tie that color scheme together.

So in the end I was able to save the poor fella and give him a new outlook on life. I think he was happy with the restoration as I was too. For having come right in on budget without spending a cent the jack received a custom touch and best of all continues to be functional.

Raised Raw

Posted: August 7, 2012 in General
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I often believe that people who strive to succeed and excel at whatever they are doing set their sights on what is known as the “top “in the social media. For example musicians may compare themselves to the “top” artists of their genre and then work to achieve, or surpass, the level they have set for themselves. I often think that things that are considered to be the pinnacle of there category are sometimes at the top because of marketing and business strategies that have allowed them to reach the masses. These days it would seem that marketing and business play more of a role in “success” then the actual thing or skill.

I take great comfort in believing that the greatest of all things are done by individuals that will never be recognized. I believe that some of the greatest musicians are those that sit on their couch and play for themselves. I believe people have created, built, and invented many things that will never be viewed by the public. These people have done these things simply because they have given 100% of themselves to their dream. Marketing and business are not a factor. I also take joy in believing that there are people out there oblivious to the “public standards” that have been set and they have surpassed these “standards” totally unknowingly simply because they have worked within their limitations of greatness.

For a long while now I have found just about everything on television to be rather boring. Lately when I have found the time to sit down and kick back I have been browsing the videos on Vimeo. I have been able to find lots of very cool, well made, inspiring videos from independent videographers.  I stumbled upon a video by Adam Richards entitled Shinya Kimura who is a Japanese born custom motorcycle builder. The video reminds me of the raw greatness that drives people to achieve extraordinary results in what they are passionate about.

The film is fantastic to watch as it displays raw material, “real” tools, a passion, no design department, feeling, imagination, and soul. The subtitles are great to read and the images and sounds are exceptional, I only wish I could smell the fuel, oil, and hot metal. The film demonstrates the product of someone who was “brought up surrounded by the smell of oil and steel”. I guess some people were just born lucky.

So when you have 3 minutes to spare blow this video up to full screen and crank up the volume. Should any of you happen to be iPad users then I encourage you to watch it on your tablet however make sure you are holding onto it throughout the duration as the vibrations from the engine that come through to your hands makes it feel like your on the bike. Enjoy!