About two years ago I got serious with the project. Yesterday, I took it for the first ride.
Here's the result:
Lots of major problems with the motor. Rusty and crusty. The magnesium / electron oil pump was completely disintegrated into what looked like concrete bits - it was GONE just the gears left, and that stuff along with mud was everywhere in the motor. The front cam bushing carrier was also toast (it's also magnesium). Later, I started to make a new carrier on my small manual machines, but Mark Huggett started offering new replacements just then (!). The oil pump gear cover was seized into the casting and required welding on a nut and major torque, and then some thread repair in the casting (a huge 38mm tap, if I recall).
The first set of (matching-each-other) barrels were cracked base to top (!), the frame I used needed straightening and a bad tube replaced, my cam was shot and good replacements are difficult to find. Also, many of the used parts I had bought over the years were only good for reference. So, some lessons learned. And building a bike from nothing adds a lot of difficulty to begin with... this is just a sampling of the gripes
My friend Jeff Moore was a huge help with this project. The case blasting and repairs, cylinder and top-end machine work, tank stripping and lining, CAD plating, and his patience with me, and probably many other things I'm forgetting, were his contributions. Thanks Jeff.
I tried to do as much of the work as I could in my home shop. I learned a lot, which I will apply to the next one.
It needs more tuning and shakedown, but my short ride yesterday reminded me that yes, it was a fun project.
-Chris
That came out great! Man you work fast!!!!