Some of the small parts on the bike are not original parts, which required me to order some new parts.
Friday, 16 October 2015
Some Bolts and Nuts ordered.
Hi
Some of the small parts on the bike are not original parts, which required me to order some new parts.
Some of the small parts on the bike are not original parts, which required me to order some new parts.
Sunday, 11 October 2015
Assembly Started
Hi.
I have started to assemble the WL. Here are some photos:
You will notice that the head cups are a silver colour - they were cadmium plated (or silverish) when the motorcycle came out of the factory. Most of the nuts and bolts were parkerized (black).
On this photo you can see the brake pedal and the foot board. Notice that the zerk fitting (grease fitting) is silver as well - the fittings were cadmium plated when the motorcycle came out of the factory.
On this photo you can see the foot clutch, foot board and the clutch cable.
The last photo is from the back of the motorcycle, showing the rear crash guard and the rear brake rod.
I have started to assemble the WL. Here are some photos:
 |
| The Frame: Front Side |
 |
| The Frame: Right Hand Side |
On this photo you can see the brake pedal and the foot board. Notice that the zerk fitting (grease fitting) is silver as well - the fittings were cadmium plated when the motorcycle came out of the factory.
 |
| The Frame: Left Hand Side |
 |
| The Frame: Back End |
Frame Repainted
Hi
I have reached a significant milestone in the restoration of my 1941 Harley-Davidson WL - I have stripped the paint from the frame, sanded the frame and resprayed the frame in the matt desert khaki colour.
Why a milestone? What this means is that I have completed the disassembling of the motorcycle and can now start with the assembling of the motorcycle!
To strip the paint off the frame I used an extra strong paint stripper that I applied with a brush. After about 10 minutes I then used the power washer to blast the loose paint off. I had to repeat this process twice before all of the paint was off.
 |
| The Frame: After Stripping the Paint |
This was late Friday afternoon. On Saturday I took a wire brush on the drill and I cleaned every nook on the frame to make sure that there was no rust anywhere. This was very laborious and it took maybe 4 or 5 hours to clean the frame. I then used a clean rag and thinners to wash the entire frame clear from any dust or residue.
 |
| The Frame: After Stripping the Paint |
This photo clearly shows how the frame was constructed in the factory - sections of pipe was fitted into the castings and then brazed (the copper / golden colour is the brazing).
 |
| The Frame: Front casting - Cleaned |
 |
| The Frame: Engine Casting Cleaned |
I then sprayed the frame in the matt desert khaki (2 coats). One coat was laid on during Saturday afternoon, while the second coat went on Sunday morning early. Because the paint is an epoxy paint I have to wait about 8 to 12 hours before the paint is hard (the chemical reaction takes time). I'll wait to this afternoon and then put the frame onto blocks for the re-assembly.
 |
| The Frame: Painted - Left Hand Side |
 |
| The Frame: Painted - Right Hand Side |
Again - this is a significant milestone!
Sunday, 4 October 2015
Next Up - Engine Rebuild and Frame Repainted
Hi
I have arranged that the engine will be rebuilt by a guy that have restored about 100 Harley-Davidson's from the 1940's and 1950's. I will take the engine to him Saturday week, so that the can start with the rebuild.
While he is busy with the engine, I will:
I have arranged that the engine will be rebuilt by a guy that have restored about 100 Harley-Davidson's from the 1940's and 1950's. I will take the engine to him Saturday week, so that the can start with the rebuild.
While he is busy with the engine, I will:
- Strip the paint for the frame;
- Paint the frame in the Matt Desert Khaki;
- Strip the paint from the fork;
- Paint the fork in the Matt Desert Khaki;
- Assemble the for to the frame;
- Strip the paint from the handlebars;
- Paint the handlebars in the Matt Desert Khaki;
- Fit the handlebars to the fork;
- Fit the already painted front fork;
- Fit black-painted springer fork springs,
- etc.
- etc.
Engine Out, Handlebars Off and Fork Off
Hi
I've been down with a bout of flu, but have managed to:
I've been down with a bout of flu, but have managed to:
- Take out the engine;
- Take off the handlebars (Bruce Palmer warns that the handlebars are a tight fit - and was he correct!);
- Take off the front fork.
 | |
| Picture of the Motorcycle Frame - just the gearbox still in it! |
Tuesday, 29 September 2015
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").
Here is a list:
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
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