New BoardTrack Project w/Honda Engine

We removed the flywheel from the engine with a gear puller.
PDR_0267.JPG

Used a hacksaw to remove most of the fin material.
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Fabricated a tapered arbor and faced off remaining fins on the outer portion on the lathe. Decided to leave the fin detail in the center a little proud in order to avoid cutting into the center ribs.
PDR_0270.JPG

So far so good, may need to dress up the center of the flywheel a bit.
PDR_0273.JPG

Will start on a cover for the ignition next.

Mike
 
Now you could make up a cover that looks like an old Vellocette Venom. The faux pushrods could also be moved to this side...would fool a lot of people.
 
Nowramfg, if you can, post a picture of the Vellocette Venom. Be interested to see what you have in mind.

We fabricated a cover for the center of the flywheel from aluminum plate.
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Tapped two hole in the flywheel and attached the cover plate with two flatheads.
covers up the remaining ribs nicely.
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Mike
 
I raced 1 of these in the 60's in Australia....
you could use this design also...
jap_500.jpg
For those that are interested..
These frames were made from bicycle tubing, 1" in diameter, and fully brazed, butt joins.
The head bearings are bronze bushings, the front forks are a simple 7/8" tube sliding inside a 1" tube with a long coil spring inside, and a long bolt from bottom to top. They had about 1 1/2" travel at most. Note that there are no brakes, no kill switch, and they had no chain guards....
My left ankle was mauled badly by a primary chain in 1966...almost severed my foot!!!!
Kill switches on lanyards and primary chain guards were implemented in the next few years.
These motors were 500cc, ran on Methanol, and produced 52HP. The frames occasionally cracked but were mostly trouble free.
 
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Those are both great looking bikes. We went back and forth over engine mod on whether to give it an OHV look or a flat head look. In the end we decided on the flat head. Here is a single Model B Harley engine that we took cues from.

1926 HD B26 Motor B.jpg

Mike
 
Fabricated a 2 piece ignition cover out of aluminum. Note the hole created for the ignition wire from the top and bottom pieces.
PDR_0277.JPG

Attached the larger piece to the engine with a small tab on the bottom. The top is attached to the bottom piece with acron nuts. Also replaceed bolts holding the ignition with acron nuts and threaded rod. May try to wrap the ignition wire in a material to look the part.
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Shot of the whole bike with the final mods to the engine.
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Other side of bike with final mods to the engine.
PDR_0284.JPG

Mike
 
Looks pretty close to the 1/2 way point, maybe closer to 3/4 of being done. What do you have in mind for paint? All of your mods look real nice. A lot of work for some small details, but worth it.
Getting much sleep at night thinking about what to do next, or maybe I should of did this? :-{
I know how it was for me. Keep pluggin along, your almost there.
 
Finally back to the bike build after a nice long Christmas break. Hope you guys had a great New Years.

We are nearly finished with the mechanical build. A few items left and we will be ready for a shake down and test run. BTR, I guess we are about 3/4 they way to finishing the project. If I had to do this again, I think I would start with a custom frame. There were a few limitations we had to work around due to the frame.

Developed and internal throttle for use with the standard 7/8 bars. The throttle is fabricated from 1" dia. delrin bar stock. The internal ID is closely matched up to the OD of the bars. A shoulder bolt is threaded into an interal delrin piece and will be cut flush to the OD of the throttle.
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A hole is drilled into the bar where the throttle cable is run through and attaches to the interal throttle. A brass clamp is fabricated to hold the throttle cable at the neck.
PDR_0291.JPG

Fabricated a chain guard from flat stock.
PDR_0295.JPG

Fabricated brackets to hold the guard in place attached to the engine.
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Decided not to cut of the output shaft off from the engine, but fabricated brass spacer/washers for a more vintage look. Check out the fabricated brass and steel components on the throttle.
PDR_0301.JPG

We hope to have a trial startup & run this week. Plan to take video and post it as soon as we can.

Mike
 
Glad you are back, Really nice work.

I am optimistic that your improvements to the cooling of the head will be enough to keep it cool. I really hope that works. I like all the other touches you have added as well. It is really looking like a vintage motor.

If it were me I would have prefered the exhaust to be a bit longer and curl down similar to this.
Cyclone

Also if you note that on the Cyclone the handlebars are flat. The upsidedown cruiser bars always look like just that. Upside down bars which for me detracts from all of your other fine work. I really like the velocity intake and the brass accents.

I think this is going to be a beautiful bike and a pleasure to own when finished. What color are you going to paint it?
 
Clotho,
I agree about the bars except there were several mfgs early on that used them that way. Again, on most MB projects it looks just bad.
Dave
KC
 
^^^ I'm going to agree as well. Heres an idea from a bike I'm building right now.
DSC01506.jpg

Gives that drop look you're all after, without looking "upside down".
DSC01523.jpg

Real simple bends to roll, but would be just as easy to cut and piece together one or two sets of bars to get the flow right.
 
That intake seems familiar somehow. I enjoy and respect your craftsmenship and fabrication. Looking good!
 

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