Revised, Revised To-Do List

Hi

The To-Do list is getting shorter and shorter - from an earlier post titled "Outstanding Work" and "Revised To-Do List":

• Complete the spray-painting of the front fender and fit it;
• Complete the dash board rebuild;
• Complete the re-wiring of the motor-cycle;
• Assemble the rear rim and put a tyre on;
• Complete the front rim and spokes and assemble the rim and put on a tyre;
• Refurbish the handlebars and fit them, with the control cables;
• The heads still have to be torqued;
• The seat must be covered and fitted; 
• Fit the fuel and the oil tanks and connect the various hoses;
• Fill the battery with battery acid;
• There is a small adjustment that I have to make to the exhaust to ensure that it fits properly;
• And I have to fit the horn;
• The couple of parts that I need for the front brake has arrived and I must fit that.

I could not take the Harley WL to Doepie for a final check on the 27th August 2016, due to the small number of missing parts on the front brake.  But these parts have arrived. At the moment I'm thinking of taking the motorcycle to Doepie for a once-over on either the 10th or the 24th September. Should all be fine, we will start the bike at that time.

Wish me luck!

Plan for the Week

Morning 

My plans for this week are as follows:

• I will drop the front rim, hub and spokes off at the guy that has respoked the rear wheel. He should be able to finish the respoking of the front wheel by Friday afternoon.
• On Saturday I'll take the two rims, pick up the inner tubes and have the tyres fitted and balanced.
• I want to pop in and visit Doepie to see how he is doing. I have one or two small items that I want his help with.
• When I get back to the house, I will fit the two wheels.

I'll then have a rolling chassis!

The following week or two I'll finish up the outstanding items and get the motorcycle ready to start the 24th September.

Front Rim Spray Painted

Morning

I have spray painted the one side of the front rim yesterday and am busy mixing Celemix for the other side.

Dispatch Rider Patch in Wall Hanging

Morning

Today I went to fetch the patch and the vintage tyre levers.

I want to use the patch and some of the other memorabilia to put together a man cave wall hanging - similar to the one that I have done for my 95th Commemorative Edition Sportster.

In this wall hanging I have fitted the following items:

• Top left is a 95th Commemorative Edition patch. 
• Below that is a 95th Commemorative Edition pin. 
• Bottom left is a post card of the 95th Commemorative Edition Sportster. 
• Bottom right is a Maistro model of the 95th Commemorative Edition Sportster. 

In a similar wall hanging of the WW2 SAUDF Harley-Davidson WL, I would like to put together the following:

• A short history of the H-D's during WW2 service in the SAUDF, with some WW2 photos of the H-D's in East Africa, Madagascar and North Africa. I'll include the Dispatch Rider's patch, the early WW2 SATC badge and some of the other memorabilia in this collage. 
• A summary of the restoration process with a before photo, some photos that I took during the restoration process and an after photo. I also want to use some of the packaging of the NOS parts that I have used in the restoration process. 
• I have managed to get a Maistro model of a 1942 WLA (see post “1942 Harley-Davidson WLA Memorabilia”. I will include this in the collage as well. 

What do you guy's think of such a man cave wall hanging? Anything that you would suggest that I include in the wall hanging? 

Busy with Another WW2 Article - The Disappearance of the UDF Harley-Davidson's

Hi

As I have mentioned before, I have done a lot of research on the use of Harley-Davidson motorcycles by the Union Defence Force of South Africa in World War 2.

I'm currently busy writing my last article on the use of H-D's by the SAUDF in WW2. The SAUDF procured 4,500 H-D's early in WW2 and has used the motorcycles in the East Africa and Madagascar Campaigns. 

They were then moved to North Africa to fight against Rommel (nickname was the Desert Fox). This ding-dong campaign between Britain and Italy / Germany saw Italy gaining valuable ground into Egypt initially. 

The British then pushed them back hundreds of miles into Libya. When Rommel arrived on the scene he quickly took action and pushed the British back into Egypt. 

A small contingent of Australians managed to hang on to Tobruk - a small town with a deep harbour in the Mediterranean Sea. The British managed to resupply this force until it was relieved later.

But this meant that Rommel had to supply his Panzers with fuel and ammunition from a harbour about 400 kilometres to the west of Tobruk. His supply line was about 800 kilometres long. 

After replenishing their forces, the British pushed Rommel way back into Libya. Rommel then replenished his forces and went on the offensive again. But... This time he realised that he has to capture Tobruk and it's harbour. The British have since replaced the Australian troops with two divisions of South African troops (almost 30,000 troops).  So... Rommel focused his entire Panzerarmee on Tobruk. 

Read what happened in the article.

Dispatch Rider Patch from World War 2

Good morning

I was really lucky to buy a British Dispatch Rider patch from WW2 on eBay a while ago. This is what the badge look like.

WW2 Dispatch Rider Patch

This looks very similar to the insignia worn by motorcyclists in the Union Defence Force in both World Wars - see post titled "SA Motocyclist Insignia".  After all - the Union Defence Force of South Africa formed part of the British Forces and used a lot of British kit in WW2.

I want to mount all of the memorabilia, some of the NOS packaging, and a short history of the Harley-Davidson's that serviced the Union Defence Force of South Africa in the East Africa, the Madagascar and the North Africa Campaings in a frame that one can hang on a wall.

Wiring Completed

I'm finished with the wiring (except to connect the horn, once I have mounted it).

What a finicky job!

Note to self - don't do this ever again!

Fitting the Rear Light Harness

Hi. 

I'm busy connecting the rear light harness to the tail lamp. 

Exploded View of Tail Lamp

I have managed to pull through the two wires to the tail lamp. 

Test Fitted the Dashboard Cover and Tanks

Hi. 

I'm finished with the wiring of the dashboard and have test fitted the dashboard cover and tanks to see if I have to shim the dashboard. 

It is fitting like a glove and is really looking great. Judge for yourself. 

Vintage Tools have Arrived

Hi. 

I have collected a parcel with a number of vintage tools that I have bought over a period of time. Some eBay'ers in the continental USA doesn't ship internationally and I have shipped these tools to a friend of mine is the USA. He graciously collected the parts and after all the parts have arrived at his house, he shipped all of the tools in one parcel to me. 

In the process I saved hugely on shipping costs, as the shipping cost for the individual tools would have been more than 3 times what I paid for the one parcel. 

Here is a photo of the vintage tools. 

Note the NOS package for the chain breaker. Still in the "For U. S. Ordnance" packaging. 

The toolkit is coming along nicely. Here is a photo of the tools. 

 

This is seriously starting to look like an early WW2 H-D WL Toolkit.

 

Not shown above is the tyre levers (on it's way). What I am missing is the following:

•  The spark plug spanner;
• The Rear Wheel Lug Tyre Wrench.
• The tappet wrench.

 

Fitting the Front Terminal and Wiring

Morning. 

I'm busy with the front terminal. I have fitted the terminal (the horn is mounted to the terminal). Here is a photo. 

The 1941 WL Horn Mount

Hi. 

Last night I had a good look at the horn mounting to try and figure out how the lot all fit together. The best exploded view that I could lay my hands on for the early models (prior to 1941) are provided below.

Exploded Views of the Horn Mounting

This is not the 1941 WL Horn Mount, but it is very close. This exploded view was in the 45 Restoration Company catalogue.

I have test fitted the horn mounting and it looks pretty much like the photos that Palmer have in his book. Here is a photo of the the horn with the horn mountings fitted. 

I'm going to fit the top mounting and connect all of the wires to the horn terminal. I will have to install the front fender before I can complete the horn installation. 

Palmer on the 1941 WL Horn Mount

Hi. 

Following on from my previous post - this is what Palmer has to say about the 1941 WL Horn Mount. 

Started Fitting the Horn

Afternoon 

I have also started fitting the horn. Just a reminder:

• The Harley was fitted with a 6V car horn when I bought her. I wanted to replace the car horn with an original Delco-Remy horn and the correct Harley winged face plate.
• A while ago I managed to buy a Harley horn with the winged face plate a while ago. It went very cheaply, but I was after the winged face plate - not the horn body as it was not Delco-Remy.
• After watching eBay for more than a year, I managed to buy a used Delco-Remy 16 6V horn (without the face place) - see "Finally, a Delco - Remy 16, 6 Volt Horn".

Between these two purchases I can assemble an original Delco-Remy 16 6V horn, with an original Harley winged face plate.

The first step to fit the the horn was to fit the horn bracket and thread the horn wires through the bracket. Here is a photo. 

 

Steering Dampener Fitted

Afternoon 

This is what the steering damper assembly looks like in the parts manual.  I have sand-blasted and re-sprayed the individual parts and have assembled them to check if they fit properly. 

I've actually fitted the steering dampener. I initially thought that I need a steering dampener spring, but when I test fitted the steering dampener unit, I realised that the spring was actually still in the fork. 

Fitting the Tyre Pump

Morning. 

In a previous post "Vintage Air Pump for Toolkit" I have mentioned that I have managed to get a used, brass motorcycle tyre pump on eBay. 

The pump has arrived a week or so ago. I have taken it apart, resprayed the pump body black, greased all of the parts and reassembled the pump. It is working great!

With the pump working, I have fitted the pump, using the original pump clamps that I have sandblasted and painted many moons ago. 

Here is a photo - notice that I have used friction tape on the rear crash bar to prevent the clamps from sliding around.

More Parts Ordered

Hi

I have ordered the following from 45 Restoration Company in the USA:
- an angled zerk fitting
- a lock tab washer for the right springer fork
- the front brake adjusting screw that is missing
- a zerk fitting extension with the specific zerk fitting that fits the extension
- a steering dampener spring
- the fibre washers for the steering dampener
- a spring for the brake pedal.

I've asked them to ship the parts with international priority shipping.

Fitted Brake Cable and Oiler - and hit a Snag.

Hi. 

I have fitted the front brake cable and the oiler - see the photos on the previous post.

An Exploded View of the Front Brake Assembly

An Exploded View of the Brake Cable Oiler

But I then ran into a snag. I'm missing a couple of crucial brake components - which means that I have to order a couple of parts from the USA (see post “More Parts Ordered”). 

It normally takes about 6 weeks from the time that I place the order until I have the parts in my hand. Which means that my time frame to have the bike completed will be extended by about 6 weeks.

I'm disappointed, but it is what it is. I'll try to place the order for the two parts tomorrow.

An Overview

Hi

This is how she looks at the moment.

Revised To-Do List

Hi

The To-Do list is getting shorter and shorter - from an earlier post titled "Outstanding Work":
•    Complete the spray-painting of the front fender and fit it;

•    Complete the dash board rebuild;
•    Complete the re-wiring of the motor-cycle;
•    Assemble the rear rim and put a tyre on;
•    Complete the front rim and spokes and assemble the rim and put on a tyre;
•    Refurbish the handlebars and fit them, with the control cables;
•    The heads still have to be torqued;
•    The seat must be covered and fitted; 

•    Fit the fuel and the oil tanks and connect the various hoses;
•    Fill the battery with battery acid.
•    There is a small adjustment that I have to make to the exhaust to ensure that it fits properly;
•    And I have to fit the horn.

If I want to take the Harley WL to Doepie for a final check on the 27th August 2016, I have to finish the above in the next couple of weeks.

We have a public holiday tomorrow and I would like to do the following:
•    Mount the front brake assembly and fit the front brake cable;
•    Run an earth wire from the dash board to the front light, as the WL has a 3-wire front light unit that requires an earth;
•   Connect the rear light;
•   Clean up the wiring;
•   If I have the time, I would like to finish off the front fender;
•   Spraypaint the front spokes, the front rim and possibly the front fender.

I can then have the front wheel re-spoked during the rest of the week.

Which means that I can have the tyres fitted this coming Saturday (the 13th August).

That leaves the rest of the To-Do list to do on the 20th August.

Wish me luck!

Fitting the Front Brake Handle

Hi. 

I'm on a roll. I have also fitted the front brake handle and the cable clamp. I'll fit the cable during the week. 

Re-assembling the Headlight Toggle Switch

Hi. 

I'm busy with the headlight toggle switch.

The Headlight Toggle Switch in an Exploded View

I've soldered the three wires (an earth in the centre and two positive wires on either side). 

Re-assembling the Horn Button

Afternoon. 

I'm busy with the horn button.

The Horn Button in an Expolded View

I have already soldered the horn wire to the button. And spray painted the button a matt black. Here are some photos:

Prepping for Paint

Evening. 

I'm bushed. Been working on the vintage Harley all day:

1. I cleaned all of the loose chrome off the steering damper with the Dremel and a small grinding stone. Then sandblasted all of the parts of the steering damper. This will be painted black. 

2. I also took apart both the horn switch and the headlight dim / bright switch. I lightly sandblasted the copper parts of the switches, to ensure that they make good contact. I also sandblasted the outer covers - this will be painted black. 

3. I soldered the horn wire to the horn switch. Tomorrow I will solder the headlight switch wires to the switch. 

4. The front rim has been prepped for painting - the matt desert khaki colour. 

5. I also prepped the rear wheel to have the tyre fitted. 

6. And I have fitted the seat.

It has been a very busy day.

Preparing the Rear Rim for the Tyre

Hi. 

I have touched up some of the small marks that were made when the spokes were fitted and have taped the spoke well with black tape to prevent the inner tube from chaffing. 

I have managed to get two inner tubes with the thick rubber valve to fit the vintage rim.

I'll have the tyre fitted and balanced this coming week. 

Here is a photo or two. 

Fitting the Seat

Morning 

The seat has been covered and is ready for fitment. This is the original seat that was on the motorcycle that I have sandblasted and resprayed almost a year ago.

Step 1 is to fit the bolts

Canvas Saddle Bags Fitted

Afternoon. 

I have collected the WW2 canvas saddle bags from Faik (one of the bags have a name and a 1942 date written on the bag). He has done a fantastic job on the bags. 

I could not wait to fit the bags on the vintage Harley. Here are some photos. 

The reason for the smaller bag on the left hand side is that I still have to fit the brass fire extinguisher on the left hand frame. A big bag (like the one the right) would have been too big. 

Fitting the Rear Light Harness

Morning. 

Today I want to finish the wiring. One of the outstanding wiring elements is the rear light harness. I have to pull the harness through the channel in the rear fender. 

H-D WL Seat Covered

Morning

Faik - he must be around 70 years of age - has completed the covering of the seat. He does not have a machine in his workshop at home - all his leather work is done by hand stitching.  He has also done some repair work on the WW2 SANDF helmet that I have bought on Bid or Buy.  Here are some photo's of the saddle and the helmet.

I will collect the above items from him this afternoon and can fit the seat during the coming week.