Finishes on 1941 UDF SA Harley-Davidson 45” SOLO U-Model

Hi

I have been doing a lot of research on how the 1941 Harley-Davidson U-models were supplied to the Union Defence Force (primarily from Bruce Palmer's book "How To Restore Your Harley-Davidson").

Photo of UDF (SA) Harley-Davidson from Bruce Palmer’s book

Here is a list:

DISTINCT FEATURES

Distinct Features of the SA UDF Harley-Davidson U-models:

·         Iron heads                                                                                                            Black

·         Civilian-style 7-inch round dry mesh air cleaner assembly                               Khaki?

·         Clutch release lever with one hole

·         Long front fork legs                                                                                            khaki?

·         Ride control                                                                                                                 ?

·         16-inch wheels with star hubs                                                                              khaki

·         Front stand                                                                                                            khaki

·         Rear stand with sand pads                                                                                   khaki

·         Gas tank no drain plug                                                                                         khaki

·         Speedometer without trip meter and black and silver air plane-style face

·         Clutch release lever with one hole

·         Civilian-style tail lamp (bee hive)                                                                          khaki

·         Front licence plate                                                                                         olive drab

·         Early luggage rack (tubular style)                                                                        khaki

·         One piece inner primary chain cover                                                                         ?

·        Bolts are mostly parkerized

·        Early type horn

DID NOT HAVE

The motorcycles did not have:

·         No black out lights

·         No front fender lamp

·         No rear chain oiler

·         No skid plate

·         No oil-bath cleaner

·         No aluminium heads

·         No speedometer with trip meter

·         No windshield

       ·         No leg shields

KNOWN 1941 HARDWARE FINISHES

Motor

Black Painted

·         Cylinder Sleeves                                                                                           8 @ #057

·         Cylinder Heads (Iron)                                                                    #9-40M & #10-40M

Cadmium Plated

·         Tappet guide screws                                                                                      8 @ #057

·         Timing gear cover screws                                                                           11 @ #056

·         Timing plug                                                                                                     #2326-38

·         Oil pump spring caps                                                                                                   

·         Feed oil pump studs and nuts                                                                                      

·         Crankcase relief pipe screws                                                                        4 @ #036

Parkerized

·         Head bolts

·         Head studs and nuts

·         Cylinder base studs and nuts

·         Crankcase studs and nuts

·         Crankcase bolts

·         Crankcase drain plug

·         Oil pump bolts

·         Scavenger oil pump studs and nuts

·         Upper and lower motor mount bolts, washers and nuts

·         Top motor mount bracket

·         Top motor mount spacers

Silver Painted

·         Oil pump bodies

·         Tappet blocks

Natural Finish

·         Crankcases

Carburettor

Cadmium Plated

·         Manifold                                                                                                       #1107-36A

·         Manifold nuts                                                                                          2 @ #1115-32

·         Lever screws                                                                                                                

·         Low speed lever bolt                                                                                                    

·         Bowl lock nut                                                                                                  #1268-29

Parkerized

·         Mounting bolts

·         Support bracket

Natural Finish

·         Carburettor body

·          

Air Cleaner

Khaki Painted

·         Air Cleaner Cover – Main colour scheme

Parkerized

·         Air cleaner backing plate

·         Air cleaner mounting bolts and support bracket

·         Mounting bolt lock plate

·          

Exhaust

Transmission

Cadmium Plated

·         Shifter rod end bolt and nut                                                                                          

·         Tank shift lever stud nut                                                                                               

·         Transmission side cover screws                                                                                  

Parkerized

·         Shifter rod end nut

·         Shift gate screws

·         Tank shifter lever stud

·         Transmission shifter cam shift lever

·         Transmission mounting studs, washers and nuts

·         Transmission adjusting bolt

·         Transmission top cover screws

·         Transmission filler plug

Black Painted

·         Kick starter arm

·         Kick starter spring

·         Foot clutch bearing cover

·         Foot clutch release spring

Silver Painted

·         Transmission Side Cover

Natural Finish

·         Transmission case

Starter Crank and Pedal

Parkerized

·         Starter pedal axle cover

·         Starter pedal axle

·         Starter spring stud

Clutch

Parkerized

·         Foot clutch pedal

·         Bracket

·         Washer

·         Release spring

·         Spider washer

·         Cable ends

·         Cable housing

·         Clutch release lever

·         Clutch release bolts and lock washers

Sprockets and Drive Train

Parkerized

·         Primary chain cover screws                                                                                #037

Frame, Safety Guards and Stands

Cadmium Plated

·         Grease fittings                                                                                                              

·         Control coil clamp screws                                                                                            

·         Primary chain inspection cover screws

Parkerized

·         Head cone nut

·         Rear stand hardware and catch

·         Front stand hardware and catch

·         Complete jiffy stand (except spring)

·         Safety guard U-bolts and nuts

Black Painted

·         Frame

·         Rear stand

·         Jiffy stand

·         Front stand

·         Foot board rivet

·         Safety guards

·         Saddle pan

·         Buddy seat yoke clamps

·         Seat T

·         Ride control knob

·         Handlebars

·         Handlebar spirals

·         Inner primary chain cover

·         Outer primary chain cover

·         Primary cover inspection plate

·         Clutch cover

·         Rear chain guard

·         Tool box

·         Tool box bracket

·         Muffler

·         Muffler clamps

·         Exhaust pipes

·         Exhaust pipe clamps

·          

Frame Head

Cadmium Plated

·         Neck cups

Parkerized

·         Steering damper rod

·         Steering damper spider washer

Forks

Cadmium Plated

·         Steering damper washer                                                                                #2784-30

·         Steering damper large nut                                                                             #2785-30

·         Steering damper screw                                                                                  #2781-37

·         Frame head bracket                                                                                                     

Parkerized

·         Plate, rocker                                                                                        2 @ #2636-36N

·         Spring, upper                                                                                       2 @ #2618-30A

·         Spring, cushion                                                                                       2 @ #2620-37

·         Spring, bumper                                                                                       2 @ #2622-30

·         Spring, buffer                                                                                           2 @ 2622-36

·         Rod, spring                                                                                             2 @ #2631-36

·         Bushing, spring rod                                                                                 2 @ #2632-31

·         Nut, spring, rod, acorn                                                                         2 @ #2634-36N

·         Ride control slider washer

Black Painted

·         Fork legs                                                                              #2605-40M & #2607-40M

Stainless Steel

·         Ride control sliders

Handlebars and Controls

Parkerized

·         Handlebar clamp nut

·         Handlebar pinch bolts and end nuts

·         Spark control coil frame clamp                                                              #3344-26 (45)

·         Control coil clamps                                                                                        #4162-30

Natural Finish

·         Front brake hand lever and bracket

Tank, Fuel and Oil

Khaki Painted

·         gas tank – main colour scheme                                                                                   

·         oil tank – main colour scheme                                                                                     

Cadmium Plated

·         Gas valve spacer                                                                                                         

·         Gas shut off knob screw                                                                                              

·         Gas shut-off rod seal cap                                                                                             

·         Oil tank drain plug                                                                                                        

·         Oil line tank nipples                                                                                                      

·         Vent line banjo bolt

Black Painted

·         Tank top strip                                                                                               #3502-37B

Parkerized

·         Tank top plate bolts                                                                                 #3532-18 (45)

·         Gas tank mounting bolts and nuts

·         Chain oiler screw

Mudguard / Fender

Painted

·         Front fender – main colour scheme

·         Rear fender – main colour scheme

Parkerized

·         Front and rear fender mounting hardware

·         Mud flap screws                                                                                                           

Toolbox

Parkerized

·         Tool box mounting screws and washers

Chain Guard

Parkerized

·         Sprocket cover

·         Sprockets and sprocket nuts

Seat Post

Parkerized

·         Seat mounting studs, bolt and spacers

·         Seat T pivot bolt and nut

·         Seat clevis pin                                                                                                #3111-29

·         Spring, Seat clevis pin                                                                                    #3112-29

Foot boards

Parkerized

·         Footboards

·         Footboard studs

·         Footboard support rods

·         Foot clutch sidebar

·         Rear brake sidebar      

Rear Axle, Brake and Wheel

Cadmium Plated

·         Rear axle adjusting screws

·                    

Parkerized

·         Rear axle and nuts

·         Axle sleeve and nuts

·         Axle sleeve collar

·         Axle spacer

·         Star covers

·         Star cover screws

·         Rear brake pedal

·         Pedal bracket

·         Backing plate anchor and nut

·         Rear rod and clevis

·         Clevis pin

·         Brake rod lock

·         Brake drum socket screw

·         Brake actuating lever and cam

·         Brake pivot stud and plate

·         Brake rod shaft lever and cam

Khaki Painted

·         Rim

·         Hub

Front Axle, Brake and Wheel

Cadmium Plated

·         Front brake lever pivot bolt and nut

·         Front brake cable clamp washer                                                                                 

·         Front brake lever bracket screws                                                                                

Parkerized

·         Front axle and nuts

·         Axle sleeve and nuts

·         Axle sleeve collar

·         Axle spacer

·         Star covers

·         Star cover screws

·         Front wheel adjusting lock nut

·         Shackle

·         Shackle bolt and nuts

·         Brake cable adjusting screw

·         Brake cable lower connection

·         Clevis pin

·         Brake cable oiler

·         Brake actuating lever and cam

·          

Black Painted

·          

Khaki Painted

·         Rim

·         Hub

Instrument Panel

Parkerized

·         Instrument panel mounting hardware

·         Dash cover mounting screws                                                                      #4505-39a

·         Dash cover mounting bolt                                                                              #4518-36

·         Wire clips                                                                                                        #1602-30

·         Wire clips                                                                                                        #4727-30

·         Wire clips                                                                                              2 @ #4730-30a

·         Wire clips                                                                                                       #4728-25,

Speedometer

Parkerized

·         Cable clips                                                                                                    #11136-36

·         Cable clips                                                                                                    #11136-39

·         Drive retainer and screw

Electric

Cadmium Plated

·         Horn mounting screws                                                                                          #031

·         Horn cover bolts and nuts                                                                                            

·         Headlamp mounting washer                                                                               #0228

·         Generator end cover screws                                                                                       

·         Spark cable packing nuts                                                                                             

·         Headlamp and horn switch cover screws                                                                    

·         Headlamp bracket bolts                                                                                 #3475-36

·         Stop lamp switch screws                                                                                             

·         Battery terminal screws and nuts                                                                                 

·         Battery cover wing nuts                                                                                               

·         Ground wire frame screw                                                                                            

·         Frame terminal screws and nuts                                                                                  

·         Dash cover left hole plug                                                                               #4518-38

·         Horn terminal screws                                                                                                   

·         Relay mounting screws                                                                                                

·         Relay terminal screws                                                                                                  

·         Front fork wire clip                                                                               2 @ #4703-38A

Parkerized

·         Circuit breaker mounting bolts

·         Ignition coil U-bolts and U-bolt straps

·         Relay terminal screws

Black Painted

·         Generator steel body

·         Generator end cover

·         Generator mounting strap

·         Battery case

·         Battery cover

·         Headlamp body

·         Headlamp mount                                                                                           #4966-36

·         Tail lamp body

·         Horn body

·         Ignition coil

·         Ignition coil mounting plate

·         Stop lamp switch spring

·         Voltage regulator cover

·                    

Natural Finish

·         Generator commutator end piece

·          

Battery

Parkerized

·         Battery cover clamp bolts

Wiring

Horn

Parkerized

·         Upper And Lower Horn Brackets

·         Horn Bracket Mounting Bolt                                                                                  #066

·         Screws and nuts                                                                                                    #051

·         Horn Spring Plates                                                                                         #4861-29

·         Horn Straight Plates                                                                                       #4862-29

·         Horn Curved Plates                                                                                       #4862-31

Headlight and Taillight

Parkerized

·         Headlamp mounting nut                                                                                      #0134

·         Headlamp bracket bolts                                                                               #13457-36

·         Tail lamp body screws

·         License bracket

·         Stop lamp switch

Speedometer

Cadmium Plated

·         Lamp knob stem                                                                                                          

·         Lamp knob screw                                                                                                         

Accessories

Cadmium Plated

·         Tire pump clamp wing nuts.

Black Painted

·         Luggage rack

·         Mirror head

·         Mirror arm

·         Mirror clamps

·         Tyre pump

Parkerized

·         Luggage rack screws and nuts

·         Luggage rack studs

·         Windshield clamp bolts, spacers and nuts

·         Windshield apron clamp                                                                               #11307-41

·         Tire pump clamps and bolts                                                                                         

 

Refurbished Bolts and Nuts

Hi

This weekend I have also managed to finish refurbishing a number of nuts and bolts:

Re-assembling the Jiffy Stand

Hi

I have also re-assembled the jiffy stand.  Interestingly, Bruce Palmer says on Page 138 of his book "How To Restore Your Harley-Davidson" that the Harley-Davidson's that were supplied to the Union Defence Force from about the middle of 1941 had a longer than normal jiffy stand.  But my Harley-Davidson was manufactured early to mid 1941 and have been fitted with the shorter jiffy stand.

Bruce Palmer on the UDF WL Jiffy Stand

The Jiffy Stand of my Early 1941 WL seems to be the short stand.

Re-assembling the Footboard and Foot Clutch Assembly

Hi

This weekend was very productive.  I have, among others, assembled the foot clutch assembly.

The Foot Clutch Assembly of a Harley-Davidson WL (circa 1940;s)

Here are some photographs of the foot clutch assembly:

The Foot Clutch Assembly, as you would see it on the left hand side of the motorcycle

The Foot Clutch Assembly, from the back - note the 2 @ spring star washers

Just out of interest sake - I have looked at what Palmer wrote about the foot clutch assemblies in his book "How to Restore your Harley-Davidson" (see picture below).  The foot clutch lever on the above assembly is like the one on the left.  Again, circa 1940's.

I then fitted the left footboard with a rubber Harley-Davidson Oval mat.  Bruce Palmer, in his book "How to Restore Your Harley Davidson" states on Page 149 that the Harley-Davidson factory introduced the steel footboard mats in 1943 due to a rubber shortage.  My Harley-Davidson was manufactured in 1941 and the bike would have been supplied to the Union Defence Force of South Africa with rubber mats.  Which is the reason why I fitted the rubber footboard.

Bruce Palmer states that the steel mats were introduced in 1943.

 
After fitting the footboard mat, I completed the left footboard and foot clutch assembly.

The Footboard Mat Fitted

The Entire Left Footboard and Foot Clutch Assembly (with clutch cable) - inside view

The Entire Left Footboard and Foot Clutch Assembly (with clutch cable) - outside view

Front Fork was also Manufactured in 1941

Hi 

I have finished spray painting the front fork and was reading about the front forks in Bruce Palmer's book "How to Restore Your Harley-Davidson". 

On page 102 of the book, he has a table (see picture below) of the forging numbers of the spring fork bracket. From the table it is clear that forks manufactured in 1941 had either a 5, 6, or 7 on the forging. 

Table on Page 102 of Bruce Palmer's Book

I took a picture of the forging and the forging die number of my H-D WL is TC-20TF 6 (see picture below). Which means that the front fork was manufactured in the middle of 1941.  This corresponds to the time when the frame of my H-D WL was manufactured - see post "The Frame of my Harley-Davidson WL was Manufactured in 1941"!

  

 

Picture of my H-D WL Springer Fork

Re-assembling the Rear Brake Light

Once the spray-painting of the rear light was completed, I re-assembled the rear brake light:

• The copper light fitting was really rusted and I sand-blasted that and then spray painted it in a brilliant white - mainly to improve the reflection from the bulb;
• I then re-fitted the wiring into the fitting;
• Fitted the original red glass into the housing;
• Fitted a replacement see-through glass for the number plate light;
• Completed the assembly.
  

The 1941 original red glass lense and the original retaining wire fitted

The flip side - note the Harley-Davidson stamped on the top of the 1941 original steel cover

The re-assembled brake light housing (the stamping is more visible on this photo)

More Parts Spray Painted

Hi There! 

I've been very busy this weekend and have sand blasted and sanded a lot of parts and have started to spray paint the parts:

• Matt Desert Khaki:  I have finished spray painting:

• The rear light;
• The battery box and lid;
• The dash board cover;
• The gearbox level mount against the gas tank;
• The tank insert;
• The throttle spiral;
• Both caps;
• The chain guard;
• The air cleaner cover;
• etc.
• Matt Black:  The following parts have been spray painted (but I smudged some items and will just have to sand and spray these parts next weekend):

• The seat;
• The seat T-bar;
• The entire brake assembly;
• The air cleaner mount against the carburetor;
• The bars on the springer fork;
• The coil mount and bolts;
• The U-bolt mounts and bolts for the crash bars;
• A variety of nuts and bolts.
  

First Parts Spray Painted

Hi There

On Saturday I have managed to spray-paint the first batch of parts.

I have bought 1 liter of Celimix Matt Black to paint the parts that came out of the factory as black with.  The slight gloss on the photo's is because the paint is still a bit wet.  The parts that I have sprayed this week are:

• The kick start arm (far left);
• The side stand with washer, bolt and nut;
• The right and left footboard arms;
• The kick starter;
• The clutch arm with nuts.

I have also bought 3 liters of Celimix Matt Desert Khaki and the parts that I have sprayed so far are:

• The rear brake drum;
• The front headlight ring;
• The headlight mounting bracket;
• The toolbox, including the hinge pin (just below the front number plate);  
• The battery box lid;
• The headlight;
• The front number plate;
• The springer fork; 
• The rear crash guard (hanging on the ladder);
• And the skid plate (also hanging on the ladder).