Project '15 M.E.C.

Have got a bit more done in between other things.
Needed to make a fuel tank like the one in the book, so got a piece of 150mm exhaust tube.



I cut some ends from 1.2mm sheet slightly larger than needed (easier to trim some off than weld some on) and clamped between some old car discs. I used ball bearing race and a piece of shaft under the press to make the ends dished.




I split the 150mm tube and a piece of 38mm tube and tacked them together with the ends.


I cut a piece of 1 1/2" threaded pipe and welded into the side. I bought a brass end cap and machined the hexagon off and knurled the edge to look like the old style caps.


Slung the tank under the frame top tube with a couple of 160mm exhaust clamps to make sure it all fitted.

 

Have the engine rebuilt with some new seals, gaskets and bearings. Removed the drive gear (much heating and bent my 3 leg puller) and bought a new pulley.

Using the boring bar set at 6 degrees I bored the taper to fit the crankshaft.

This cut out most of the keyway, so using a junior hacksaw and an old broken pin punch ground down to a small chisel I remade the keyway in the taper.

Cleaned up with the edge of a flat file and fitted to crankshaft.

I made the engine mounting plates from 6mm 5005 spec alloy sheeting (it was what I had on hand) and fitted the engine in position. Took a fair bit to bend it (too thick for my metal folder) in the vice with a block of hardwood and 4lb hammer, but it turned out spot on for the belt alignment.

I reused the original muffler, just in a different position. I made two plates from 5mm steel plate cut to the same size, fitted one to the barrel and muffler. Bought a 90 degree bend from the muffler shop, cut to fit and welded in. Welded two mounting plates that bolt through the front engine mount bolt to the body of the muffler.

Now waiting on the handlebars to arrive so I can position the seat and footpegs.

 

Handle bars and seat fitted.


Found these 'old style' reverse levers on fleabay.

Now have seat and bars positioned the next bit will be to make and mount the footpegs.

 

Have been a bit slack lately but got excited when the mudguards arrived from Austria and have made the brackets and fitted. Also bent some tubing for a rack and made a belt cover for the front pulley. Have ordered foot peg rubbers and will make the mounts and fit them when they arrive. Looking more like a bike now.

 

Got a bit excited a couple of days ago and stripped it down. Took the frame and bits to be sandblasted and picked them up this morning. Home to wash down and out with the spraygun while the weather is good. Been a busy day but all the black done now. Tomorrow (if the weather is good) colour.

 

Too wet, cold and windy today to do any more painting so I started putting the frame bits together.

The headstem (weld and fake it) came out pretty good after the sandblasting and a couple of thick coats of paint.

 

Almost done, just waiting on a couple of bits in the post. Have to find the throttle lever I put away so carefully last year and make a throttle cable.

 

Dunno about Texas, but maybe Bunnings next Sunday if the bits arrive in time.

 

Got a Calendar?

 

Got it started today. Has bulk compression and hard to turn over to get a good swing at the handle. Runs nice with a nice two stroke burble.