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Thread: 1940 SS Knuckle

  1. #261
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    i'm going to have to admire the picture then lol
    for some reason I have a thing for shift knobs. any kind of weird thing I find I think shifter and if I can drill it for an insert for the rod.

  2. #262
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    Scrambling trying to get the engine together and working on 3 things at once. Seat at at upholsterer, tins are at painters. Focusing on trying to get the engine built so that I can get the exhaust and foot controls built.

    Here are some things that happened in the past week:

    Made some special stud covers to close off the holes in the CE reg I modded.



    Started working on some floorboard pedal thingers:





    Always a shame grinding off (semi) pretty welds





    I got this cast exhaust piece that I designed. It goes underneath the trans and will have vbands on both ends.



    I welded my vband flanges that I made a few posts back to the head. Super high stress job. Took about 7 hours. Preheat, weld 3/8", back in the oven, repeat, then slow cool down cycle. Welds looked good and no cracks. Then I powdercoated them wrinkle black which may not be everyone's thing, but I like it. Valve guides and rocker shafts are one-off... I have a plan coming together there. Rocker shafts are out getting carburized now.



    Last night I bead blasted and prepped the case for glyptal. Me and my buddy Dave at BA enterprises put new Jim's main races in the case and honed them. Cover bearings reamed, lots of threads fixed, etc. Hoping to put the bottom end together this weekend. I think I have all the parts.






  3. #263
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    This is motorcycle porn...

  4. #264

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    Quote Originally Posted by FatChibs View Post
    This is motorcycle porn...
    Truth

  5. #265
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    MADE IT TO THE FINAL SIX!

    Been working hard.

    Got everything from the cylinders down together permanently. Motor is rebuilt from the flywheels up. Doing all the motor work at BA Enterprises in Lockport NY. He's very knowledgeable. Waiting on valves before I can do final top end assembly.

    Here's how it sits now.



    But Dave was going out of town for Oley for the week so I brought the motor back home to start on exhaust and foot controls.

    Fits in the frame well. Had some concern about the vband clamp clearance but I think I am golden.



    I'm running an MM74E and if you have ever used one you know there is a little round spacer that goes under the mag bolting flange. It's purpose is to be able to drop the body to install the mag head. Well that idea is great but the spacer leaves a lot to be desired. I replaced it with this:



    Next, I committed chopper blasphemy and machined some adapters to reduce my top end oil feed ports from 1/2-20 to M10x1.25. I did this because there are a lot of awesome banjo bolts available in that size, and I don't have time to be making bolts right now. Time is running out.



    Last night I finished up my footpeg/floorboard/pedal things. You may remember these from a few posts back:








    Hope to get them mounted and have some functioning linkage in the next week or so, then on to the exhaust.
    Last edited by xnewmanx; 04-28-2017 at 9:01 AM.

  6. #266
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    .... ....

    Got a Goodson Alum Mag Cap on the critter.

    It's kinda fat compared to the plastic cap.
    Being the EL have short jugs, was there a fitment problem installing it ...??

  7. #267
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    Quote Originally Posted by Dragstews View Post
    .... ....

    Got a Goodson Alum Mag Cap on the critter.

    It's kinda fat compared to the plastic cap.
    Being the EL have short jugs, was there a fitment problem installing it ...??
    Don't know yet haha. Might not be able to run it or grind it down. I put the mag on then put the heads on. Heads are empty still.

  8. #268
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    is that the cam cover your going to run?
    oh, and those foot controls are beautiful. must have taken some time to fab and polish.

  9. #269
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    Kinda a cool cam cover being it was used only for one year on the Knucks (1940), Later on in the runs of the early Pans they was brought back into use....

    My 52 has one on it ...

    Last edited by Dragstews; 04-28-2017 at 9:38 PM.

  10. #270
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    Quote Originally Posted by nuklhd View Post
    is that the cam cover your going to run?
    oh, and those foot controls are beautiful. must have taken some time to fab and polish.
    Yes. It's the correct cover for these cases. It's a little beat up but I like it that way.

  11. #271
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    The swiveling floorboard has a braking or shifting function i hope?

    My 53 also has that cam cover.

  12. #272
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    Ok, got some work done the past couple days.

    First things first I had to mount the footpegs, so I started by cutting out some ľ 316 on the saw, then smoothing it and bending it up.







    Then I welded on some gussets:



    Then did a test fit. Seems to be going well so far…





    Then I polished them up. This video shows what they looked like after polish. https://www.instagram.com/p/BTh-Uhjl...en-by=ctnewman

    After that, I mounted the floorboards on.






    It’s shocking how skinny it is!



    Then it was time to make some brake linkage. All I used to make this was an angle grinder, a drill press and a bandsaw.







    Then I made some more pieces… here’s a bit more detail, should be pretty self explanatory.





















    Then welded those parts on a part I made on the lathe, blended the welds and polished them:




  13. #273
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    I wanted some unique clevises, so I had to make those as well. Hereís how I did that. Turn OD



    Use grooving tool to profile



    Sand smooth



    4 pieces done



    Then put in the mill in the rotary table and slot and drill.



    The last step I didnít take photos for, but I put the part back into the lathe and profiled the rest of it with the groover and sander. And this is how the parts looked when done and ďinstalledĒ



    Then I had to make mounts for the master cylinder and the pivot linkage. I did the math to have the end result of the braking force be equal to that of my sportster, which is comfortable to me,
    based on leverage ratios, master size, caliper pot size, etc. Fab tip: itís often helpful to fab small brackets and things while they are still attached to the stock which is helpful for clamping, drilling, sanding polishing, etc. Also, protip 2: donít smash your thumb while changing brakepads on your car.



    Hereís a video of the actuation of the master:

    https://www.instagram.com/p/BTvYai1F...en-by=ctnewman

    After that it was time to build a front portion of the front pipe. I had a midsection cast off a 3d printed wax model, bolted that to the frame, then built a pipe from 304 using vband flanges to mount
    it. I had to make the flanges but used an off the shelf clamp.
    Here are several shots of the exhaust.















    And hereís a tool I made to make cutting tubing easier and more accurate. First, set the angle and lock it down.



    Then add the hold down ring and clamp that down. The whole plate slides in the miter groove of the saw and you get perfectly radial cuts every time.



    You need one for every CLR tube you have, and every diameter, but since I really only build Harley exhausts, I made 1.75 OD X 2,3,4,6 CLR. I need to make a 1.75CLR still.


  14. #274
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    Made a top motor mount. Nothing fancy here. I wasn't feeling exceptionally inspired when I was designing it.







    Used 1/8 filler rod which made blending the welds a lot simpler than the welds on the foot control bracket. Also made a fixture to hold everything true because I knew I was going to be putting a lot of heat into it. It pulled a little bit, but it pulled evenly, so I will probably have to run a .030 shim behind the center bolt.



    Fit well. There will not be an issue with the rocker tins interfering...





    Then got it polished up. Polish only took 3 hours which isn't bad.








  15. #275
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    this is getting out of hand. I have sensory overload

  16. #276
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    Man i'm learning tig welding and to fabricate stuff for my bike for passion in the weekends.... but your work are incredible and out of this world.
    Great job

  17. #277
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    Unreal man!

  18. #278
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    Aaaaaa ... I don't mean to rush ya.... But time grows short for "Bore Free"

    Click image for larger version. 

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  19. #279
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    I'm tryin! I got the clutch linkage almost wrapped up, hope to finish that tonight, took all weekend.

    I have to finish the motor, hopefully this week.

    Clutch linkage (almost done) (1 more day)
    Install valves and finish top end. (3 days)
    Add drain bungs on frame (.5 day)
    Leak test frame (.5 day)
    5th trans mount (will have to be sort of funky, I think) (one day)


    Once I have the tins back:
    Front pipe rear section (1 day)
    Shift arm (1 day)
    Oil lines: once complete send to nickel plate w/ knuckle nuts (1 day)


    Once I have the motor complete:
    Rear pipe (1 day)
    Carb support (.5 day)
    Finish bird deflector (.5 day)


    Any time:
    Grips (1 day)
    Kicker pedal (2 days)
    Gas Cap (1 day)

    End:
    Seat closeoff (1 day)
    Wiring and taillight mounting (1 day)
    Bars (1 day)


    I have to leave in 35 days.

    Definitely running low on time!!!
    Last edited by xnewmanx; 05-15-2017 at 1:20 PM.

  20. #280

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    Man, you are truly insane, the amount of detail on this build is out of this world!

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