Re-assembling the Dashboard

Hi. 

The first step is to install the insulation washers on both sides of the base. 

Then the bulb bracket. 

Then the insulator. 

Next the bulb contact spring. 

Followed by a bolt with a washer. 

And the other bolt with a NOS dash wire and a washer. 

Flip the dash base over and install the insulation washers.

Followed by washers and copper nuts. 

The other side is slightly different. Again the two insulation washers have to be installed. 

Then the two rivets, etc.

And I then soldered the NOS wire to the rivet.

Lastly I soldered the other wire to the switch.

This is what it looks like with the dash panel fitted, with globes and the light reflectors in place. 

Plans for this Weekend

Hi

The weather service is forecasting very heavy rains for Cape Town this weekend.  Which means that I will not be able to do any spray painting (the rear rim is ready for spray painting).  But there is still a lot of work that needs to be done.  I have the following in mind:

• I would like to fit the rear brake to the frame and then slide in the brake assembly.  I have not been able to do this, as the thread of the rear axle sleeve nut that allows one to fasten the brake assembly to the frame was damaged.  But Doepie kindly re-threaded the nut and cleaned the damaged thread on the axle sleeve for me (see photo below).  I got the parts back this week.
• I also want to start with the rebuilding of the dash panel base - the refurbishment kit has arrived.  This will allow me to thread the wires through the correct holes in the dash panel and to connect the wires to the various poles on the switch.
• If I have time, I would also like to attach the rear brake pull switch to the bike and fit the spring and pull fire.  Not sure if I will get to this though.  Sometimes the silly things takes a long time, as you have to fit, adjust re-fit, re-adjust until the parts fits perfectly.

Rear Axle Sleeve and Nut

The Rear Brake Pull Switch

Morning 

The rear brake pull switch that I have ordered has arrived. 

But where does it fit and how does it work together?  I took this photo from a photo of a 1941 WL in Palmer's book. 

On this photo you can just make out the pull switch. It sits just below the oil pump and the spring is attached to the pull switch, while the pull rod is attached to the spring on the one side and to the brake pedal on the other side. I still have to figure out how to attach the pull switch to that location. 

This is what the location look like. 

You can jump to the post on the actual fitment of the pull switch by clocking on this link: 

Rear Brake Pull Switch Fitted 

Outstanding Work

Hi

I have the following still to do (in  no particular order):

• 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;
• Fill the battery with battery acid.

I will then be able to take the motor-cycle to Doepie to go through and do the final adjustments.

Once he is happy with everything we will be able to start the motor-cycle.

I am still aiming for early September 2016 to start the motor-cycle.

Tyres

Hi

After a long drawn out search I have managed to get 2 tyres. 

Note:  The tyres were on display at a local motorcycle dealer.

Last Parts Ordered (I Hope!)

Hi

I have ordered some of the last parts that I need to complete the re-build:

The Horn Mount Bracket, including the front junction terminal

The washers, etc., that I need for the junctions on the seat post that connects to the battery and some other wires.

Rear Rim Ready for Paint

Hi

I have finished sanding the rear rim -  manufactured in January of 1941.

Switch to Fork Harness

Hi

Today I want to finish the rear rim and at least get a primer on.  But I will multi-task and also fit the switch to fork harness. 

This is what Palmer says about the wire installation. 

I have wired it as shown in the photos. 

Rear Wheel Spokes Refurbishment Complete

Hi

I have come across 11 new rear wheel spokes in a spare parts box that came with the Harley-Davidson WL when I bought it.  These spokes were galvanised, but they were in a very good condition.  I just removed the galvanising and then painted the spokes matt black.  I have now managed to paint a total of 43 rear wheel spokes - this gives me an extra 3 spokes for in case a spoke or two snaps when the wheel is assembled

This coming weekend I want to focus on painting the rear wheel rim.  I can then send the rear hub, the set of spokes and the painted rim for re-assembly and truing.  This is not something that I want to attempt on my own.

Re-assembling the Headlight

Hi. 

This is what the headlight assembly looks like in the parts manual.

Exploded View of the Headlamp Assembly

I have received the headlight reflector (part 4922-35) and have installed that, along with the bulb connector (part 4935-35). 

Next I fitted a new 6V bulb.

Then the lense rubber seal.

I then fitted two clips at the 8 o'clock and the 4 o'clock position 

Voila! 

Another Overview

Fitting the Speedometer Cable

Hi. 

In order to 'lash' (Palmer's words) the generator to switch wire to the Speedometer Cable, I had to fit the Speedometer Cable.  Here are some photos. 

Refurbishment of the Rear Spokes

Hi. 

In between all the other work, I have been sanding the rear spokes and have managed to paint 21 spokes. 

Switch to Generator Harness

Hi. 

Next up is the switch to generator wire. 

This is what Palmer says about the wire installation.

I have fitted the green wire to the "Switch" terminal post on the generator and the red and black wires to the relay. Here is a photo. Note the wire clamp on the down tube to keep the wire in place.

I then pulled the wiring through the dashboard hole and taped it with friction tape to protect the wiring from chafing.