72 Combat Proddy Build

Re: 72 Combat Proddy Build- It begins...

Ok, horn and rear fender sorted.

horny-situation-t6228.html
rear-fender-issue-t6236-30.html



With the rear tail light housing on, that is pretty much the rear fender area. I'll look at some bikes at the races tomorrow for the wiring path for the rear light.

Next up is sorting the rear wheel. I have the correct dummy axle so I need to reassemble the brake (the bearing was removed). Once that's in I just need to assemble it. I'm missing the spacers on the speedo side so it won't really get buttoned up, but it'll get close.

Re: 72 Combat Proddy Build- It begins...

Just keep moving, just keep moving...

Re: 72 Combat Proddy Build- It begins...

Hi Dave,

Noticed your rear light fairing is not the production racer abbreviated type. If you are going to use a PR seat/tail unit?, may not fit.

Re: 72 Combat Proddy Build- It begins...

illf8ed said:

Hi Dave,

Noticed your rear light fairing is not the production racer abbreviated type. If you are going to use a PR seat/tail unit?, may not fit.

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They don't come trimmed, apparently. So, yes, to use the seat I will need to cut it.

Re: 72 Combat Proddy Build- It begins...

swooshdave said:

swooshdave said:

I am going to give away two (2) sets of the airbox bolts. Just be the first two people to PM me with your address. Sorry, but US only.

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First set is going to Pennsylvania.

Click to expand...

Second and last set is taken.

Manifold bolts are still available.

Re: 72 Combat Proddy Build- It begins...

I need a set of 4 intake manifold allen head bolts...

Re: 72 Combat Proddy Build- It begins...

grandpaul said:

I need a set of 4 intake manifold allen head bolts...

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I think I can arrange that.

Placing an order with Clubmans for some shocks and taillight and ignition switch. Placed order for some wheel spacers with a local shop. Need to order some stuff from Old Britts and then I can start wiring in anger.

Re: 72 Combat Proddy Build- It begins...


Final shot of this side before I start working on the other side. Just mocking up but it looks, well, not bad.


Chaincase empty. But it seems to fit really well. I need to get the gasket for the crankcase to confirm final shimming but so far so good.



Can't wait for the next parts shipment! I"ll be a lot happier once the rear wheel is on the ground, so to say.

Re: 72 Combat Proddy Build- It begins...




Moved the adjuster to face forward.


Kickstarter acorn nut...

Looking for a good spot for the ignition switch


Remembering I have the stock bracket that was removed from the airbox. Making my life a whole lot easier.



So, tail light on. Fit's with Proddy seat.
Shocks on.
I know where the coil will go. Need to build a bracket.
I also need to tackle the front forks. I have the gaiters and got the O-rings for the headlight brackets.
Need to mount the Podtronics unit. Don't know where.

When I get the parts for the rear axle (on order) I will finally be able to get her on her feet. Might even pull the bike down so I can sit on it and make "vroom, vroom" noises. :mrgreen:

Re: 72 Combat Proddy Build- It begins...

I like to slap the basic parts on 'em and roll out in the sunlight for a couple of photos when they get to the rolling stage; motivational stuff...

Re: 72 Combat Proddy Build- It begins...

grandpaul said:

I like to slap the basic parts on 'em and roll out in the sunlight for a couple of photos when they get to the rolling stage; motivational stuff...

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I'm looking forward to the day it rolls. I should get almost all the rest of the rear wheel parts tomorrow. Which means best case it will get on the ground LATE Friday nite.

For motivation I have Paul's beautiful Proddy picture as my desktop image. 1920x1200 of "this is what you will never have, but good luck getting close.."

Re: 72 Combat Proddy Build- It begins...


Chainguard


In the battery box there is a small hole for the strap and an indent in the airbox. I thought one bolt wouldn't be enough but when I snugged it up the switch can't move. I always prefer putting less holes in the stock parts. It'll get painted black when I remember to.



Key sits up nice and tight. I won't have two keys on it, maybe a fob at the most.

Re: 72 Combat Proddy Build- It begins...

SwooshDave,
The wife said the air cleaner bolts arrived at the homestead. THANKS again.

Where the heck are you getting all of the stainless/polished button head fasteners for your build?? Are they original thread (ie, whitworth, BSF, etc) or did you go with SAE threaded fasteners?

I am like you whereas I think the new allen head fasteners look great compared to stock bolts.

Re: 72 Combat Proddy Build- It begins...

TravNorton said:

SwooshDave,
The wife said the air cleaner bolts arrived at the homestead. THANKS again.

Where the heck are you getting all of the stainless/polished button head fasteners for your build?? Are they original thread (ie, whitworth, BSF, etc) or did you go with SAE threaded fasteners?

I am like you whereas I think the new allen head fasteners look great compared to stock bolts.

Click to expand...

http://www.tacomascrew.com/

They are very, very close to the house and they have a huge selection and most importantly, they don't mind if I come in asking for one washer. For stuff they don't carry (their UNF selection in SS is a little thin) like the 3/8 buttonheads for the "Z-plate" I got from McMaster-Carr. Bu they have minimums (so instead of one I may have to get 5-10, but I just give the extras away to people who ask...) and shipping.

Re: 72 Combat Proddy Build- It begins...

Things are going slow.


Decided to tackle the front since the rear was giving me so much trouble. So apparently you can't just slip the fork ears in so everything came apart and back together a few times. Go the o-rings in so no rattling. Those astute amongst the readers will notice some key things missing from the forks, so off they came again. (It was the fork wipers/gaiters). I didn't realize they were so stiff, sadly I have a hair dryer in the garage for warming up such parts...


So I have the front wheel spacer from Paul on the disk side and I recently got the dust cover for the other side.


That's all the parts in the book, but it feels like there should be another spacer. What am I doing wrong?


If that wasn't enough I just realized that the holes for the center stand in the cradle need to be enlarged (more like made round again) to fit the later 850-style center stand bushings.


Of course with the bike assembled you can't really get a drill in there square. Sigh. I'm praying that once the bike is assembled and some weight is put on it, there might just be enough clearance to drill out the holes.

And I went at the gearbox sprocket again, with no luck. :cry:


To make myself feel a little better I pulled down the tank and seat and propped in the headlight bucket. And stuck the rear wheel on loosely.

Re: 72 Combat Proddy Build- It begins...

One step forward, three steps back...

Re: 72 Combat Proddy Build- It begins...

grandpaul said:

One step forward, three steps back...

Click to expand...

Does that front wheel look right?

Re: 72 Combat Proddy Build- It begins...

If the brake disc is centered in the caliper, it's right.

Re: 72 Combat Proddy Build- It begins...

grandpaul said:

If the brake disc is centered in the caliper, it's right.

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I might need to put the disc on to tell. The reason I ask is that without the pinch bolt on the non-brake side tightened I can move the lower in. Which is why I think there should be a spacer.

Re: 72 Combat Proddy Build- It begins...

You can't go by the gap left once all the pieces in place.
Its possible there is some bent in the yokes or stanchions
spaying out a bit at bottom.

If you detect more striction with axle nipped up than
loose, better double check fork alignment.

Glad to look at others rough tough projects, gladder it ain't me this time.

hobot