post number 90

I got some parts from my friend Ron today. Here are the toolboxes. They have to be individually fit and soldered together, but this sure beats making them from scratch.


Here are some clutch parts. They turned out well. OG clutches are steel on steel, I am having the female plates lined with kevlar. The spring plate is a machined solid piece rather than two pieces brazed together. The clutch guide is very nice, I sent Tim into aberdeen to pick up some sickle rivets for it. I am making good progress on my fork and will have some more pics later on today!

post number 74

My daddy drilled out the .625 holes in my fork diving boards, they turned out well, now I just have to cut them off and weld them on straight.


I got my muffler castings in the mail for approval today. They castings turned out really well, I told them to not grind anything off of them because they were a little excessive on the prototypes.



Here is the small end. What a cool deal. I am going to run an aluminum one on my cannonball bike, it is half the weight.




Check it!

post number 70

This is probably the last time my flywheels will ever be completely apart


Here is a pic of me pressing the crank pin into the left flywheel.



Pressed in and ready for service! I actually have to do some machine work on the other side. It is some pretty wild stuff. Photos will follow.




Here it is all together. am so excited!

post number 61 case problems!!!!

So I was checking out my right case today and discovered a crack from web to web on the inside of the case. I don't know how I missed this before, but I did. Luckily I have an earlier 1912 or 1913 case that I can use on the run.


Here is the earlier case, This has an extra rib on the bottom too, so this is probably a win win situation for me. I had to machine some aluminum away from the center of the case to make room for my bearing. everything clears, and now I can send this case off to get polished.

Post number 53

My friend Delmar just delivered a bunch of goodies for the sears project. All of the parts that he made were made on a cnc machine. In most cases I ordered more pieces than I will probably ever use. Here are the screws for the tool box doors These will end up getting nickle plated.


Here are the lock nuts for the fork stem.



Here are a bunch sprocket shaft nuts. They are perfect! The rings on the left side are the bungs for my gas and oil caps. They solder into the tank before it gets painted.




Here are the bungs for mounting the gas tank and tool box.





And the really cool stuff! My bottom end. I am going to try and balance and assemble it this weekend. Wish me luck!

post number 50

I went to my friend Brad's place today to find a front drum brake and hub for my sears project. Brad has over 100 japanese bikes, so I figured I could easily find something that worked. This is the only 40 hole hub/brake combo that I could find in the whole place. It is off of a triumph 650. This thing is huge! It is a beautifully made piece that will look out of place on my sears, but it will work well and do a good job of stopping the bike!


I ordered the spokes to lace it up to my 21 inch rim from buchanans today. The center of the hub has fins in it, just like my musselman rear hub lol.

post number 45

I got my waxes in the mail today. Here is what my frame looks like, just add tubing!


Axle castings!



Seat post castings, Seat t castings and magneto/decompression castings!




Front Motor Mount Castings





And neck castings. This is all very exciting stuff and I am happy to be working on it.

post number 44

Here are the castings for fork struts for a sears. I bought some reproduction fork struts for an indian when I first started this project, but they are different from sears! I borrowed an original paint fork and pulled a mold off of one of the struts. They will turn out well!


Here are the rocker waxes. I built up the front of them to make them sturdier for my race bike. I had an original one that cracked in that spot.



Here are a bunch of waxes that broke on their way over here. I will send them back to dan and they will get melted down and turned into something else. I am really bummed about the fork pieces breaking, I was really looking forward to moving ahead with that project. Luckily I have enough stuff to keep me busy!




This is like seeing a picture of a bunch of dead bodies, it breaks my heart:(

post number 43

I got a package in the mail today from my friend Steve in CA. he sent me his patterns for sears mufflers. They are really beautiful, but I have no idea how they work! All of the parts that I cast are lost wax. Patterns like this are totally new for me. I am sending them to my foundry at the end of the week.

This is for the end piece, it is very nicely made.



Check out the nos linkages that Steve set me up with! They are for my carb and magneto linkages





Here are the baffles.

post number 38

I welded up my first prototype gas tank. I am not very pleased with it, but it is still really cool to see it in the frame!!! I learned a lot about what not to do as far as bending the blanks. The next one will surely be better! I am glad that I ordered twenty blanks lol

Here are the pliers that I made to bend the sides. They work well and clamp the metal evenly, one thing that i did not for see happening was the metal next to the bend distorting. I am learning so much about metal work with this project, I love my job!

post number 32

I got one of my spare engines from Tim Spacke today. It is really nice! Thanks Tim!


Here is what the bottom end looks like all tore apart, you can see the inner and outer flywheels, which are held in place by a big ball bearing and a pin.



Ryan polished all the bs off of my spokes yesterday. They turned out well.

post number 26

My intake towers were really pitted up, so I spent some time sanding them down before I send them off to get nickle plated. They turned out pretty good, there are some little nooks and crannies that I still have to get in, but the Pat can handle that.


HEre is my float bowl, it had three holes rotted in it. I brazed it up and metal finished it back down. It still has to be plated.