Build Thread: Dax IV w/Electra Coaster 1-spd

[rangefinder]

Picked up plumbers tape this weekend. I wrapped 3 or 4 around, and tightened it up. The C-Clip in the second from the top slot. Good start point?

I will be getting the SBP "O-ring" 3 pack. Either going to use them in addition to, or in the place of, the tape. Going to block out air leaks before they give me a headache. I read the rings work better than the tape, especially if your making "on the fly" adjustments to the C-Clip. The tape just tears up.

The tensioner is in the shop so I can get the holes drilled.
I am going to cut a slot in the wheel for the chain to ride along.

The clutch roller thing, I need a piece of angle aluminum to get that going.

 

[rangefinder]

I have my spring tensioner just about completed.
Need to grind down the wheel on one side to clear the bike's downtube.
The spring will get shortened up once the motor and chain are mounted.

My Brooks B67 saddle is on it's way back from getting the nose pin replaced.
Hopefully get that here this week.

The weather is finally starting to break, But it's still wet and cold.

Still need to get O rings and Throttle from SBP.

I have a laundry list of things I want to do still.
But need to get the break in started!!!

 

[rangefinder]

I will mention that if I had to do the clutch cover part over again...,
I would have left more room for the spring hole.
My hacked design is not nearly as nice as the one available for sale.

I appreciate all the more the work put into the original!!!
My sincere thanks for turbobuick's creation.

 

[maniac57]

Picked up plumbers tape this weekend. I wrapped 3 or 4 around, and tightened it up. The C-Clip in the second from the top slot. Good start point?

I will be getting the SBP "O-ring" 3 pack. Either going to use them in addition to, or in the place of, the tape. Going to block out air leaks before they give me a headache. I read the rings work better than the tape, especially if your making "on the fly" adjustments to the C-Clip. The tape just tears up.

The tensioner is in the shop so I can get the holes drilled.
I am going to cut a slot in the wheel for the chain to ride along.

The clutch roller thing, I need a piece of angle aluminum to get that going.

Personally I think this is overkill. I have never seen a carb that leaked enough around the slide to notice. I have even run them with the adjuster removed and the hole in the cap exposed with no problems at all.
The place you should be sealing is the carb to manifold joint. This is the source of 90% of all air leaks in HT's.
But if it makes you feel better, I see no reason no to. Just be careful not to crossthread the cap searching for the threads. The tape can make it easier to get it started wrong.

 

[rangefinder]

Got you there Maniac, It was more difficult to thread on with tape.
Even though the threads are quite wide, you can still mess it up.
I appreciate your input where the problems are to be found.
Knowing where I actually need to focus in on, thank you!

I am really thinking of ordering that shorty intake from Manic Mechanic.
It's got that O-ring right on there already.
I remember reading the NT carb likes to be in closer to the manifold/port.
Not sure that is true or not.
But the porting on that intake has to be better than my effort on the stock one.

Next Friday is the goal for the final build.

I'd really like to get that SBP throttle before then,
but I am not going to let that hold up the build!

 

[rangefinder]

Pretty psyched now... My Brooks saddle is back from repair!
This should be the perfect saddle for the cruiser.

 

[rangefinder]

Spent my lunch messing around with the build.
Specifically the clutch cable and replacing the lever.

I got a brake cable made for an Aero Lever for a Road Bike.
Needed to replace the derailleur cable, too thin, from the rapid fire shifter.
I chopped off the tip of the tip of the brake wire, not the whole tip!
Just used a Dremel, sorry for no before photograph.
But you get the idea, and it works perfect.

I hooked it up with the lever in position 2, wire taught.
Still without my roller thing still... I am getting to it.
I was learning myself how to adjust the clutch yesterday.
Leaving about .125" (maybe a little less) under the Flower Nut.

I think I have a winner.
The small drive sprocket would not turn in position 2.
And it will move when I engage position 3.

 

[rangefinder]

Got a small wire to secure the idle adjustment screw on my NT carb.

 

[rangefinder]

Here is the engine, starting to pull it together some.
I am leaving the front motor mounts long for now.
Might need to put a spacer block there due to the large Electra frame.
Cannot get the mount bolted on yet due to their length.

 

[rangefinder]

I have my spring tensioner just about completed.
Need to grind down the wheel on one side to clear the bike's downtube.
The spring will get shortened up once the motor and chain are mounted.

I moved the wheel out to the end of the arm, and it's much better.
It puts the wheel past the mount now, I think...
Once it is all up on the bike, then I'll know for sure.
I can quickly make another arm if needed in house.

 

[rangefinder]

Finally..., the first steps have taken place.
The MM Motor Mount worked out exactly as I hoped.
Spring tensioner will require some chopping of the rear fender.
I found an O-ring here in the shop and cut it to size for the carb.
More to come this week. Goal is to finish build by Friday.

I am going to be doing the happy dance soon enough!

 

[rangefinder]

Anytime I think something will take an hour, I should just plan on 2!

Removed the rag joint that was assembled so long ago in this thread.
Bent the coaster brake arm to clear the bolts on the sprocket adapter.
Installed the sprocket adapter onto the hub, loosely so I can move it.
Adjusted the coaster hub to roll smooth, and not be loose.
Cleaned up super-fast because my lunch hour was up!
I did not even get a chance to take a photo all mocked up.

Here is a photo of the brake arm in the vice before I bent it.
The one in my hand is the after photo.
It's kind of hard to tell.
But it did not take much really to get it right.

 

[rangefinder]

The bike is built up and looks good. Not great though. Struggling with exhaust.
I torched it up RED and bent it a couple times, still not right.
Then ran out of time. Thought that this would be the easiest part...
I was mistaken! Will be giving it another try today.
Here are a few shots of the muffler.
Once it's all together, I'll post a completed shot of the entire build.

I did not like drilling that hole in the bars to mount the throttle.
Honestly that throttle is cheezy, and not substantial enough.
It's going to get replaced soon, but I did what I had to do.

Soldered up the CDI, Magneto, and Kill switch.
Going to start over though, got some more wire to lengthen it out.
The wires are just too short because of the bike frame size.
I will be able to move the CDI away from the engine.
And at the same time move the wires away from the header.

I have spent a lot more than 2-3 hours building this up.
Maybe I am being a bit too fickle about it coming together?
But the effort put into this build hopefully staves off future issues!

 

[rangefinder]

Well..., I got the muffler angle pretty good. It will due for now.
The angle is not perfect, cannot seem to hit the sweet spot.
But it's on and I am satisfied.

I fill up the tank, turn the fuel petcock, hit the tickle a couple times.
Ride out to the top of my street. Started to coast down the hill, release
the clutch, it turned over, and kinda starts sputters and dies.
Rode back up the hill, tried again, same result.
So, I tried again giving it some more throttle... then this happened...

The cable stop inside the throttle slid off the cable. Seriously.
I was definitely babying it. I am bummed.

So I am going to have to get a new throttle cable.
In the meantime we are going to doctor up the end of the cable I have now.
I was really looking forward to riding out to the bike shop this weekend.
So there is still hope.

 

[rangefinder]

Duane at DAX is the MAN!!!

Replacement throttle cable coming my way Priority Mail!!!

Thank you!

 

[floridaboy]

I thought you might like to see my Electra Coaster that i built in 2009. I used a Dax 80 and built the engine mount using clamps by Manic Mechanic. I also used his Sprocket Adapter with a 40 T Sprocket. I was lucky to also get one of his machined Clutch Activater. I found the Cloud 9 seat to be great. The Electra makes a great riding bike. Good luck with your build.

 

[rangefinder]

Looked at your profile and did not see your bike. And the avatar is kinda' small.
I'd love to get a look at your clutch actuator too! Please post some pic's!!!

Electra's are awesome! I hope that Trek does not ruin the brand.
I just don't think Trek has the HEART to carry the Electra brand into the future.

 

[floridaboy]

I am sorry for not being able to down load the pictures. They are in the introduce yourself Under Old Member Returning.

 

[rangefinder]

I could see you making your album while looking at your profile.
I just refreshed it until I saw them come up.

That is my bike exactly. I love it in the brushed sliver!
If you get a chance to, take a shot of that clutch actuator.

 

[floridaboy]

I have down loaded more pictures in my Album which has the clutch picture.