79cc Sportsman Flyer build

Discussion in 'DIY Home Built Motorized Bicycle (non kit)' started by Tom from Rubicon, Jun 23, 2016.

  1. Tom from Rubicon

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    Interesting point Pat, I would have been happy to Half Link the KMC Z410 Gold chain. But it would have drove me nuts aesthetically to use that one off colored link.
    Just kidding Pat, But the build instructions don't indicate Diamond brand chain. Or I missed it somehow. :)
    Shadow Conspiracy Interlock V2 Half Link chain on the other hand is total over kill, but it sure does look nice.
    Should have had some photos to post but we had a Spring blizzard 4/15/18 and today my back was causing great discomfort.
    Chiropractor and Dr. meds will get me back to work tomorrow.
    Tom
     
  2. Tom from Rubicon

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    Tony, I spent some of my formative years as a Schwinn mechanic. It was the right way or no way. I have used a pin punch and hammer but prefer the control of a breaker. Thanks for the reply.
    Tom
     
  3. Tom from Rubicon

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    Today was play with the bike day after work. Locked down the engine mount system. Now the primary drive functions as Pat expected. Got a photo of the brake arm strap I fabricated of 14ga. SS. Shadow chain breaker arrived Thursday. quality tool for breaking 1/8" chain.
     
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  4. Tom from Rubicon

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    Another pack of Shadow Conspiracy Interlock V2 Half Link chain arrived by post today. So hopefully tomorrow pedal side will be completed. Last photo is the 14ga SS brake arm strap I fabricated.
     

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  5. Tom from Rubicon

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    Pat Dolan warned me to double up brake straps to avoid possible failure. Shimano brake straps are .035" and my strap is .075" so slightly stronger. Knowing a guy who had a rear wheel failure at speed reinforced Pat's advise.
     
  6. Tom from Rubicon

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    By the way I tried to post photos yesterday. Today no problem.
     
  7. Tom from Rubicon

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    Well it seems every time I try to do something not pure Sportsman Flyer it just does not work. At least for me.
    $70 worth of Shadow Conspiracy Interlock V2 Half Link chain is a no go for pedal side. Half link was not a solution for slack chain. As per Pat Dolan's recommendation #41 Diamond Brand chain on order. Thought it would arrive today. It didn't. Good thing I had a good day at work . I won't post photos of saggy Shadow Conspiracy Interlock V2 Half Link chain. You will just have to use your imagination.
    Tom from Rubicon
     
  8. culvercityclassic

    culvercityclassic Well-Known Member

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    An easy solution to your issue is to add a chain tensioner to the pedal side chain. Use 3/16 aluminum plate cut like the one in the photo, add a roller. Attach it to the axel and tighten it down, you can adjust as needed with just loosening the axel nut. Simple stupid design but works well ...no more headaches....cash in your pocket...ha ha EA8BBECE-C500-4B46-948D-406599DB7B99.jpeg
     
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  9. Tom from Rubicon

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    Jeff, that is genius! Thank-you. I am thunder struck by the simplicity and sanitary solution. Getting good tension on both sides is the culprit. I guess when I get off work Friday (a six hour day) to my machineshop I go.
    You got a dimensional drawing you could lend me or did you just as they say " By rack of eye". Then I got to hope Pat won't dislike an alteration of his proprietary design.
    Pat has been very kind to me as I came in the back door so to speak. #41 chain did arrive today, the good stuff Diamond, all ten feet of it. Can always use it on the left side. I must say though, that half link gold chain is pure sexy.
     
  10. Tom from Rubicon

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  11. Tom from Rubicon

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    Jeff Wolf of Wolf Creative Customs posted an image of how to balance pedal chain tension vs power side, brilliant! So I had in my collection some .187" X 1" 304 SS. Jeff spect'd .187 aluminum. So mine is over kill.
    Story of my life. It took a 1/4" offset to get the roller in track with the chain. Drive train finished. on to the next challenge.Both sides the chains are running freely. forewords and backwards. That is a big deal Pilgrims. Thank-you Jeff. I needed a veteran primo builder to give me an option that will pay dividends.
    My version is not as artistic. Jeff's is arched and I know why, it is a frame clearance feature.
     

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    #51 Tom from Rubicon, May 1, 2018
    Last edited: May 1, 2018
  12. Tom from Rubicon

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    I really do like using the trick half link chain on pedal side.
     
  13. Tom from Rubicon

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    On the other forum, was told the idler was pressing the chain wrong way.
    So, after waxing the chains in a mixture of Paraffin, Bee wax, Powdered Teflon, and Dow Corning 111. When the chains were reinstalled. I tensioned the pedal side chain as I was told to do.
     

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  14. curtisfox

    curtisfox Well-Known Member

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    KOOL, drill some holes in the arm, won't look so heavy............Curt
     
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  15. Tom from Rubicon

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    Some day Curt I may poke holes in the tensioner.
    Clearer photo.
    The tensioner arm is 3/16" X 1" X5" 304 SS.
    New photo you can see the Shadow Interlock V2 chain better.
     

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  16. curtisfox

    curtisfox Well-Known Member

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    KOOL, looking realy nice............Curt
     
  17. Tom from Rubicon

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    DSCN0765.JPG DSCN0766.JPG DSCN0769.JPG
     

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  18. Tom from Rubicon

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    Keyed kill switch for Sportsman Flyer 80 to be relocated to bracket on handle bar stem. I tried to cheat the on-off switch. I'm good.
     
  19. Tom from Rubicon

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    Final set up this last weekend of keyed kill switch. The stock on - off switch was broke right out of the box. A plain kill switch is not secure, so a keyed switch is cheap insurance. Here in SE Wisconsin you can park an unchained Harley with a for sale sign and it does not move until it is sold.
     

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    #59 Tom from Rubicon, Jul 9, 2018
    Last edited: Jul 13, 2018 at 7:10 PM
  20. Tom from Rubicon

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    Clamping S.S. tubing to exhaust manifold. More photos as progress is made. I would be making more advances. But I am also doing up grades to a 1953 NAA and a Boston Whaler Cohasset.
     

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    #60 Tom from Rubicon, Jul 9, 2018
    Last edited: Jul 9, 2018

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