Fine Tuning the Carburettor

Hi

Here is a video of me driving up and down the road, to fine tune the carburettor.

Knysna Motor Show Part 2

Morning

This is going what the display looks like.

This is me being interviewed at the show. 

And some more photos of the tent. 

George Motor Show

Good morning 

It has been a while since I have last written a post on the blog - been fairly busy. 

I'm exhibiting the Harley at a motor show this weekend in George, Western Cape, South Africa. 

I'll post some photos of the show tomorrow. 

I'm exhibiting the Harley at a motor show this weekend in George, Western Cape, South Africa. 

I was the first motorcycle to set up. Here is a photo of the exhibit. Tomorrow morning I'll add the saddle bags, water bottle, binoculars and the original owners manual. 

My wife and I took a drive to the heads in Knysna this afternoon (where the river enters the sea, the river cut through about 200m of rock). There is a lookout point where you can look out over the sea and one over the river mouth towards the town of Knysna. This photo was taken looking towards the sea. 

This photo was taken from the lookout looking towards the town. 

Snag List - Headlight

Hi

Today I want to get the headlight to work.

I have found a wrongly connected wire in the toggle switch, which I have just swapped around.

But the light is not working. So, I'll investigate further.

Snag List - Horn Button

Morning

To resolve the problem with the horn button I had to buy a replacement horn button.

I've fitted the replacement horn button and it is now working.

Snag List - Adjusting the Gear Shift

Hi

On the cards for today is to adjust the gear shift linkage properly.

Last week and Saturday I wanted to take the bike for a spin around the block. After I started the engine, and while the bike was up on the rear stand, I engaged 1st gear and released the foot clutch. Everything was going fine at this point.

I then disengaged the clutch and - after a couple of attempts - got 2nd gear selected. Again, everything was hunky dory.

I then tried to engage 3rd gear, but just couldn't find the gear.

The issue is that the gear shift linkage has to be adjusted properly. I just didn't have the time to resolve this issue last week. But I want to do that today.

And hopefully I will be able to drive the bike around the block for the first time.

Snag List - Resolving the Carburettor Flooding

Morning

Last Saturday I resolved the issue that I had with the constant flooding of the carburettor - on a number of occasions the petrol started to run out of the carburettor when I opened the fuel shut-off valve.

Initially I thought that it was a problem with the needle and seat and I replaced the needle. When I tested the fitment of the needle (after replacing the needle), by sucking on the seat to see if the needle closes properly, it worked. But the problem reoccurred.

So...   I took off the carburettor and disassembled the carburettor bowl and took out the needle and seat. I then took an ear bud and installed the ear bud in my drill. Next, I put some metal polish on the ear bud and I ran the ear bud up and down the inside of the seat, until the seat was shiny. I also polished the needle in a similar fashion. I then used carburettor cleaner to clean the muck off the parts. This meant that the needle should not stick in the seat. I tested the needle and seat again and the needle did seal properly.

Snag List - Resolving the Wiring Short

Hi There!

I have been fairly busy and have not had time to provide some feedback on the restoration of the SAUDF 1941 Harley-Davidson WL.

I have encountered a couple of issues that I am trying to resolve, namely:

1. There was a short in the wiring and fuses kept popping when I switched the lights on;
2. The carburettor has been flooding;
3. The horn button has a short in it;
4. The brake light does not come on;
5. The front headlight does not come on either.

The Wiring Short Issue

There is (was) an issue with the wiring.  I used a 1946 wiring diagram for a 5 point switch (because my Harley has a 5 point switch) to wire the Harley.

Killarney Motor Show

Morning, morning

Yesterday I have exhibited my vintage Harley at the Killarney Motor Show.  There must have been in the region of 6,000 cars, motorcycles, tractors, military vehicles, etc. on display at the show.

I was supposed to display the Harley with the Cape Vintage Motorcycle Club in the pit area of the race track, but was waylaid at the entrance gate (I got there at about 7:00) and was told to rather display the Harley with the Military Vehicles.

Here is a photo of the display.

The exhibit actually drew a lot of attention during the day.  And I got roasted in the sun - I did not plan to spend most of the day in the sun, as the CVMC display was under cover. 

During the course of the day a couple of people wanted their photos taken on the Harley.  I have included a couple of photos of particular interest to me in this post:

• The one is a photo of someone wearing a SAUDF uniform as worn in South Africa during training and then in combat in Europe (South African soldiers were also involved in the Italy Campaign in 1944 and 1945);
• The other photo is of my soon-to-be Daughter-in-Law (they are getting married in January 2017). 

Note: The SAUDF uniform in North Africa was a desert Khaki colour and of a lighter material .

Update - 31 October 2016

Hi

Just a quick update:

• There is the vintage car and motorcycle show this coming Sunday at Killarney in Cape Town . 
• I have said that I will exhibit the 1941 Harley-Davidson at the show. 
• I don't want to just take the Harley to the show, as the rich military history of the Harley-Davidson's in the UDF will not come through . 
• Consequently I have prepared the wall hanging, so that I can also exhibit that along with the Harley. 
• There are a number of small issues that I have to fix before I can take the Harley for roadworthy. 

These issues are:

• Firstly , the primary cover was touching the primary chain and making an awful noise.  But I have managed to fix the problem . 
• The generator light does not go on. I'll try to resolve this issue on Saturday. 
• Then the wiring to the front does not work -maybe the cable got pinched? 

I'll try to resolve these issues over the next weekend or two. 

Harley-Davidson WL Restoration Wall Hanging

Hi

I have previously mentioned that I am busy with a man cave wall hanging for the vintage Harley.  This is what the wall hanging will look like - it is 1,200mm long and 650 mm wide and should be around 80 mm deep.

The left side of the wall hanging tells the story of the use of the 4,500 Harley-Davidson's used by the South African Union Defence Forces in the East Africa, Madagascar and North Africa Campaign of World War 2.

This is followed by the high-lights of the restoration process.

I then want to mount a number of the new old stock (NOS) part packaging in the area that does not have any photo's or text that will look something like this.
 

This morning I stopped at a print shop to have the A0 sheet printed and it came out beautifully!  I took a couple of pictures of what the end product should look like . 

She Runs!

Hi

We have started the Harley!

Switched On

Hi.

I've switched her on, but only the oil warning light comes on - not the generator light as well.

I suspect that I have a wire missing or incorrectly connected on the generator or the coil.

In addition, the horn went off. The good news is that the horn is actually working. The bad news is that the horn button is likely defective. 

But these small issues should be relatively easy to sort out next week. I just have something on just now and have to call it a day.

Petrol in Fuel Tank

Hi

I have also put some fuel into the fuel tank!

But when my wife went downstairs to the garage, she said that the garage smelled strongly of fuel. 

When I went downstairs, there was a pool of fuel below the motorcycle. I drained the fuel tank to prevent more fuel from spilling. 

But I have two issues here - firstly the fuel shut off valve is not closing properly and secondly the needle and seat is not closing properly. 

Again, these small issues can be resolved fairly quickly and easily. 

Battery Filled with Battery Acid

Hi.

The battery has also been filled with battery acid.

Gearbox Oil Filled

Hi.

I have also filled the gearbox with oil.

Filled the Oil Tank!

Hi

I have just put oil (SAE 40) in the oil tank - the first time in several years that she had any oil in the oil tank!

The oil is still very clear and it is difficult to see the oil level on the photo, but she is right on the mark! 

PS: The oil has been standing in the tank overnight and there doesn't seem to be an oil leak on any of the oil lines. 

Oil Pressure Sensor Fitted

Afternoon

I have also fitted the oil pressure sensor and can now fill the oil tank with oil.

This photo was taken with me lying flat on my back, from underneath the motorcycle. 

Fire Extinguisher Fitted

Afternoon

Today I have sandblasted and spray painted the fire extinguisher bracket and have fitted that.  Here is a photo of the bracket fitted to the motorcycle. 

Finished!

Hi

Finally! After about two years of hard work, I'm finished with the restoration work! This is what she looks like. 

Prepping, Painting and Fitting the Front Fender

Hi

I've previously done some work on the front fender (did a metal repair, panel beating, a bit of body putty repairs, removed rust, etc.) which meant that I had to take the front fender brace off. To prevent the fender from rusting, I have spray-painted the fender with a grey primer. 

Sources Used for Military History of the SAUDF's Harley-Davidson's

Hi

I have used the following sources to compile the information relating to the military history of the South African Union Defence Force's Harley-Davidson's:

“6 SA ARMOURED DIVISION IN ITALY” Scientia Militaria, South African Journal of Military Studies, Vol 4 Nr 2, 1974.  http://scientiamilitaria.journals.ac.za;

“ARMOURED WARFARE - THE SOUTH AFRICAN EXPERIENCE IN EAST AFRICA, 1940-1941” by Evert Philippus Kleynhans - Thesis presented in fulfilment of the requirements for the degree of Master of Military Science (Military History) in the Faculty of Military Science, Stellenbosch University;

My Last To-Do List

Hi.

I'm nearly, nearly finished with the restoration of the Harley-Davidson WL.  Over the next 3 weekends I have to :

• Make a small adjustment to the exhaust pipe to ensure a proper fit of the rear cylinder exhaust port - completed;
• This will require that I touch up the spray painting of the exhaust - completed;
• Fit the exhaust - completed;
• Fit the two handlebar pinch bolts - another one bites the dust;
• Fit the 3rd headlight mounting bolt and nut - and another one gone;

Tanks and Seat Back On

Afternoon

I have managed to fit the tanks, as well as, all three oil lines. I must admit that I battled with the one oil line - the line must align perfectly with the connector otherwise the nut does not want to screw onto the connector. But I eventually managed to get the line fastened.

Oil Tank Rinsed

Hi

Doepie tells a story about a WL that he restored a while back, where the oil tank had about 3 inches of sand in the oil tank. He said that when he looked into the oil tank, the oil had cut a pathway through the sand to the oil pipe.

But what was more amazing was that when he opened up the motor, the entire inside of the motor was coated with sand. Despite all of the sand in the motor, the motor was actually running before he started with the restoration!

Because a large number of the WL's were used by the Union Defence Force of South Africa in the Western Sahara desert during WW2, they did pick up a lot of sand in the oil tanks.

I really don't want sand in the newly rebuilt motor and have rinsed the oil tank:
1. I started by pouring about 1/2 litre of thinners into the tank (obviously after blocking all of the outlets) and I then swirled the thinners around the tank. After about 2 minutes I poured the black gunk into an old container.
2. I repeated this process again, using thinners again.
3. I then switched to petrol and rinsed the tank again.
4. I repeated the process again, using petrol.
5. To prevent the tank from rusting I poured a bit of oil in the tank and swirled the oil around, which I poured out.

Next, I want to fit the oil and fuel tanks and connect all of the fuel and oil lines.

Spark Plugs Connected

Hi.

I've connected the spark plugs, using the old style copper connectors with cooling fins.

If you zoom in to the spark plug on the left you will notice that even the spark plugs are vintage original Harley-Davidson branded spark plugs. 

Distributor Control Cable Bracket

Hi.

The distributor control cable is used to retard the ignition timing to around top dead centre, to enable the rider to kick start the motor.

Once the motor is running, the rider can advance the ignition timing to the required degree before top dead centre.

Without this control it would be very difficult to kick start a 45 cubic inch (750 cc) motor.

The bracket just keeps the cable in the correct position.

Carb Support Bracket

Hi.

To fit the carburettor support bracket I had to take off the carburettor. There are just 3 screws to loosen.

I then fitted the carburettor support bracket to the carburettor. This bracket just keeps the weight of the carburettor off the 3 mounting screws.

The bracket rests on the engine block between the two sleeves - in the middle of the V.

Another job on the To-Do list completed. 

Cylinder Heads

By way of background - when the motor was rebuild I had the head nuts and bolts on order. This arrived after I got the rebuild motor back. Consequently Doepie only put two of the head nuts on. I've fitted the nuts just hand tight when I received the package. But they were not properly fastened. 

OK.  Here goes.  First off is the seat T-bar. 

What I want to do This Weekend

Morning.

I'm nearly, nearly finished with the restoration work on the vintage Harley. So. The plan for this weekend is to:
1. Remove the dashboard cover, both tanks and the seat T-bar so that I can remove the two cylinder heads.
2. Then I have to put copper gasket sealant on the one copper head gasket, put the head back on and torque the head bolts to the specified torque.
3. Do the same with the other cylinder head.
4. Fit the carburettor support bracket.
5. Fit the distributor control cable bracket.
6. I can then fit the tanks properly.
7. After that I can fit the various fuel and oil pipes.
8. Then the seat T-bar can be fitted properly.

Wish me all the best for this last push.