ITSA HAPPENING

ITSA HAPPENING

ITSA HAPPENINGS


My how time flys ! We are past the Ides of March and “Et Tu Brute?” is behind us and we now have less
than 3 months to our first event. Of course my attention has primarily been bike building to get myself
up to speed after the enforced trials sabatical year.

Come May I’ll be over at Bull Hollow, searching, mentally marking, and finally laying out 50 sections
for the 2 Day event. Anyone in the area who wants to come along and help will be welcome. Give me a
call on 970 882 2483.

Bull Hollow MX Track, don’t worry we are using their parking lot for………..
…. PARKING !

Superglitz on a Bull Hollow section

We have our permit for Turkey Rock at Howard, Colorado and Ed will be doing Trialsmaster duties
there and I’m sure is itching to get going even if July sounds a long way off.

On the lower slopes of Turkey Rock

Back on my doorstep here in Dolores there is a general warming trend towards our proposed
activities. The Town Manager seems all for it and my man, Tom, at USFS lands didn’t raise any
objections when I submitted the application.

Dolores Saturday plan

With temps well up this week the snow has been in retreat and I should be able to slip along the
lakeshore and take some pictures of some of the possible sections I have in mind. Then as we move
into April and May the area will once again be inaccessable due to rising waters as the river goes into
full flood with the “run off” from the San Juans.

Two very wet miserable cold days of snow and high winds killed any photographic desires by the lake
but the forecast is for 60 + this week, crazy weather season !

With bike building at a standstill and temps above 60 along with no wind I slipped down the lake road
to see what we have. Obviously the entire area has NEVER seen a trials bike so some “gardening” will
be required similar to what we had to do when we took on the challenge of Buckeye down in Arizona.
It can certainly be done, and on my next run down there, most likely during spring break, I’ll take a walk
up some of the hillsides to see what lurks in the trees. I am very confident that we can sort out enough
quality sections for all classes.

The “black areas” in the town pic are all ponds and are lined with all this
rock which we can use and make as easy or difficult as we like

Areas by the parking lot

Heavy stuff by the lake

A lot of choices for lines

Some gardening required

Logs of all sizes

Must be a few sections in here ?

A way up into the trees …… more news after Spring Break

Should we not get permission to ride down the public highway then the start for the Saturday Trial will
be in a parking lot by the cemetery which is the dividing point between town land and USFS holdings
which are basically the cliffs and all the land running down to the shore line. Nearer town the land
bordering the lake is town property and offers a lot of rock sections with winter driftwood thrown in,
plenty of scope here.

As I have NOTHING to build at this stage today I’ll go and look at what I thought was CDOT land but
actually belongs to the town and is designated the town dump but nobody dumps there ! ….. well I
think CDOT do, piles of junk and concrete but nicely positioned to make into excellent sections for ALL
lines…… and if we get our Beginners Trials School we can break in a fair bit of the terrain pre trial.

Here are some of the piles but there are more and some other areas which are not broken concrete
and will make some interesting challenges.

You can almost imagine the line

Steps and banks

Down here, round there……. and back up there

Uphill logs

Got to be an A/B either up or down

For the “Beginners” I can promise you  “YOU” will be able to ride this by
the end of the week !

Love this one, tons of scope

TONY DOWN

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CAPTAIN ON THE BRIDGE !

CAPTAIN ON THE BRIDGE !


CAPTAIN ON THE BRIDGE !

Since the beginning of the year the Captain has ordered “ALL AHEAD FULL” with primary work on the
Enfield and then as we slipped into February Superglitz was brought into the fray, dismantled,
despatched, sold and revamped to where we are today

“All Ahead FULL”

Today marked the 3 week point since my barrel and head left Dolores for TN. Checking today revealed
that while it arrived 4 days behind schedule, it has been at its destination since  3/9/12 and progress
has been somewhat slow, or, dare I say it …… non existant. yes, thats correct, ZERO, NONE……….. you
can imagine how happy I am with that news!!! I’m almost at the point of ordering a Big Bore Kit from
Majesty and going down that road. I had been hoping for another nautical response from the phone
call………

The response I was hoping for……….. “Finished with Engine!”

The response I received

I’m as far as I can go now on the rebuild of my Superglitz so I guess in either event I end up waiting
(yet again) and all I can do in the interim is drag the faithful No Excuse Cub out of hibernation and get
that back up and running.

Very annoying not being able to complete the task on time and as I wanted, but as always when
others are involved timescales slip. So with nothing left to do on SG apart from those new rear brake
shoes the current situation is :

“ALL STOP !”

TONY DOWN

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STOKE HER UP AGAIN

STOKE HER UP AGAIN

STOKE HER UP AGAIN

With many of the Hercules tasks successfully completed yesterday today should be relatively simple
so lets get the fire burning again and conjour up Phoenix out of those ashes once more. Today’s left
over mission is the electrical side of the house, new plug cap, kill switch and change the color of all
the breather pipes.

As SG goes Bionic into 2012 I’m able to use some of the leftover electrics and croshumic drive units
coupled to mamphletic self generating power sources so often seen in the construction of Austin
Powers “Fembots”. A whole load of spare parts came up on ebay the other day and I was able to get
the majority of the offerings at a good price.

A “Joan of Arc” model with a bit of fire damage !

A non working “Britney” but I always thought these were disfunctional

This one was used in the “sawing trick” but I got her half price !

A complete owner’s workshop manual

Another minor task that needs attention while I’m waiting for the tacky yellow paint to harden is the
rear brake mechanism which is sticking, most likely caused by the high speed ingress of sand ,grit,
and snow (now rust) collected on the wintery return from Checkpoint Charlie. Wheel out job or
frustration trying to fiddle fit.

After much research and trouble shooting it seems all the problems are caused by the new Magicals
on the Majesty mounts. That being said with the swinging arm fully down application of the brake
pedal rubs on the underside of the SA, however take the machine off the stand and with the extra
weight the SA moves up and all is well. Of course I could file off a couple of thou off the top of the
pedal arm just for the purists. While playing with the system I decided to buy some new rear grooved
brakes, and my lucky day they are $14.95 with FREE shipping. Mystery items that had been in
Colorado Springs and out for delivery all arrived today along with the OKO carb shipped on Tuesday.

Not much achieved today, but as the skiing forecast is crap there is always tomorrow and I can sit
by the fire and heat shrink the throttle cables yellow. Van Gogh got the sack and the number board
was repainted by Picasso using Hammerite and looks a lot better.

Throttle cables done in yellow heatshrink, TASK 9 COMPLETE

Number board redone in hammerite, thanks Pablo ….

I know that rear brake pedal is going to annoy me so that will be the No 1 task of the morning and
then I can move onto the electrics and rear fender/mudguard assembly. If I get all that done to my
satisfaction then I’m back in the waiting game again until the barrel and head come back. Of course
I can switch horses and drag the Cub over for some attention, reoil, change the clutch cable, remove
the side panels and fit a bigger rear guard.

Three on and offs with the brake pedal and eventually its all good and I can move on to the other
left over tasks from Friday.  First problemee is the kill switch rubber has gone as hard as a rock so
time to ferret around in the ignition box and fembot spares and find another one, its red ? maybe
some fembot part but its soft and works.

A new “red thingey” for the kill switch,  Fembot bit maybe ?

Now color co-ordinate the wiring in black/yellow along with the breather tubes and its on, functional,
and all cables out of the way. Last thing a new old style plug cap and another task is done. TASKS 6
&10 DONE

Ignition wire housed in the black, breather pipes color co-ordinated in
yellow

Black tubing all the way to the coil junction



Barrel connector slips inside the 5/16 tube

All finished off with a new Lodge style plug cap

Final project of the day is the rear fender/mudguard and am I going to use the brace or not ?  On the
face of it the brace would seem sensible but it may twist and distort the plastic so this will be a task
in two halves and I will see which looks better and is more practical. All  fitted and still unsure, I’m
leaning on the side of going without, but there again the plastic could rip out of its mountings so still
I’m undecided.

Brace fits  under the plastic

With the brace

Without …….. anyhoooo, TASK 5 COMPLETE



Final solution as I’m half decided, I’ll use half the bracket !

TONY DOWN      (Hercules)

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RAKE OUT THE GRATE AND START THAT FIRE !

RAKE OUT THE GRATE AND START THAT FIRE !


RAKE OUT THE GRATE AND START THAT FIRE !

Even though its spring like with temps in the mid 60’s its time to remove the ashes from the grate and
get the Phoenix fire burning brightly once more, much to do and I need to get on. Delivery of parts has
been pretty good this week so no complaints there, now its the “fiddle factor” of making them fit.

Well lots to get on with and in no particular order here is a list of SG Honey do’s;  The labors of
Hercules are:

1. Fit new bars and grips

2. Alter Gas Gas front brace and fit mudguard

3. Cut off kickstand bracket

4. Fit new tensioner and chain.

5. Fit rear brace and mudguard

6. Redo electrics

7. Paint front number board

8. Fit new shifter + chop end

9. Heat shrink 2 throttle cables

10. Fit breather pipes

11. SSSS

12. DRINK HEAVILY

So today’s battle plan is devised and hopefully I’ll kick off with painting the number board and then
removing the bar pad from the Pro Taper black handlebars, fit them and the hebo black/white grips
and move on to the frustrations of the Gas Gas front mudguard brace. Would be nice to wrap up the
front end and then cut off the sidestand bracket….. another 4 ozs saved!  Overall I’m hoping SGlitz
should scale in at under 200 lbs bearing in mind the original was around 215 lbs for the TY250A.

So why paint the number board I hear you say ? well it’s plastic has faded from virgin creamy white to
a dullish yellow/white, the previous stickers having been removed now reveal the true white. Nothing I
have tried gets it back to original, so black it will be.

All fingers and thumbs this morning! I hope this is not the way its going to be today…… if I could have
got it wrong then I can’t think what I missed. Carefully prepared paint tray with reynolds foil, then having shaken paint to its ready state poured in prepared tray. Roller loaded and with one swipe neatly cover
fingers and knuckles while holding number plate. Paint goes on and then having stood said board up
while attempting “touch up” Van Gogh knocks it over and then manages to flip it with wet painted
fingers! Double retouch and finally satisfactory so over to the sink for clean up. The tin is open so pour excess back in but while lifting tray the black roller touches the medium oak kitchen cabinet with
resultant screams. Pan back in sink and attempt to put top back on tin…….. but alas Van Gogh’s fingers
are still slippery and the lid falls wet side down on “her” new kitchen towel……… no wonder he went
quite mad lopping off part of an ear and then finally shooting himself. TASK 7 COMPLETE

Finally painted with a lot of frustrations

Thanks Vincent, you were about as much use as Shadetree !

Now in Task 2 with much filing in a limited working area to elongate mounting holes to fit the Gas
Gas brace on the TY Mono fork legs. It will fit I tell you !!  Lots of care and so far keeping the center line
of tread nicely positioned relative to the brace……. no screw ups. Just a fraction more to go and I’ll be
there. All lined up and new screws in place, job complete….looking gooooood !  TASK 2 COMPLETE

A good hour’s worth of gentle precision filing….. but worth it

Yes ! it fits

Task 2 done! and I have to say I like it

With the mudguard completed the next task will be No 3 and involve some intense Makita work and
try not to set fire to the workshop. First undo swinging arm bolt and lower footrest stud and move out
of the way and retighten. Now I can get at the “nasty” which has to go and the frame will be lightened
once more.

.

No stopping now, the Makita is switched back to full grinding/cutting mode and all hell breaks loose
as the demonic Shade applies the torture…… “How do you like this Joan ?”

“So Joan, any last thoughts about joining Ahrma for 2012 ?”

Heretic !

With TASK 3 COMPLETE time to move on and tackle labor No 4. Suitably greased pivot point, new
spring, and on goes the revamped chain tensioner with new block. Refreshed chain follows and all
is buttoned up before regreasing and lubing. The nice noise on rotation shows no tight spots so
clean off excess and move on to TASK 8.

Tensioner with the new block/guide goes on and the chain runs through
it

TASK 4 COMPLETE

The new MSR shifter was clearly designed for the MX fleet and comes with an extended flip back toe
piece. They have, however, used a light alloy rod with graduations to “cut back” to your own desired
length. In its natural state it sticks out as far as the footpeg so two sections get the saw treatment
before fitting.  TASK 8 COMPLETE.

Two sections removed

Neat and functional

Back to the drawing board and a tidy up of the rear fender brace first cutting off all the rear light cable
retainers and then a bit of rust removal. This one can’t be done today so a little paint required before
fitting

Cleaned up and rear light tabs removed, but it needs some paint

Time for some serious hand washing before attempting TASK 1 the bars and grips saga. Bars fit
nicely having removed the cross brace rubber which I don’t like. Now with clean hands (all things are
relative) lets see if these grips are as difficult to fit as the dealer says. Well in all my years of fitting
grips these are without doubt the most difficult!! Finally with a lot of struggling they are on and
compliment the black bars and other livery to come. TASK NO 1 COMPLETE

Bars on, no problem, but boy these grips take some effort

Where we are at “close of play” Friday 3/16/12

 Time to call it a day, a little paint on that fender brace, dog walking etc, etc.  Fantastic news of the day
while pulling out some old newspapers for painting my treasured lost book “Six Days in May” appears
from nowhere. I had given this book up for lost as I could only imagine I must have lent it to someone
but for the life of me I couldn’t remember who.  The book is 25 years of the Scottish, 1970-1994 and
covers all my EIGHT rides in the event and also has the front signed by a lot of my riding companions
of the day, namely: Sammy Miller, Mick Andrews, Malcolm Rathmel, Martin Lampkin and others.

Unbelieveable joy finding my lost book

A lot of famous names and friends

….. and if you look very closely you will see my name in the Trophies
section winning the R.A. Castle Trophy and the start of my hat trick ! 

I’ll stoke up the fire again tomorrow

TONY DOWN  

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MORE ASH AND SAWING THE LADY IN TWO TRICK

MORE ASH AND SAWING THE LADY IN TWO TRICK

MORE ASH AND SAWING THE LADY IN TWO TRICK

In the deepest recesses of the workshop loft lurk two TY250A motors and although most useful bits
have been stripped, used, or sold I really needed an unmolested front sprocket tab washer. Lucky for
me one motor was still running on its original cog so the washer has only been factory bent.

New 12T and a “lightly used” tab washer

A new 12T goes on and all is well and the flywheel cover can now be replaced. Nearly all done down
stairs apart from the electrics and their new color housing but I need to wait for the bars or the kill
switch will be flopping about all over the place.

Flywheel casing back on

The time has come! The Inquisition found Superglitz guilty as charged as an Ahrma Heretic and must
face gruesome consequences of either being burnt at the stake or being sawn in two. Neither grim
prospect sounds at all pleasant and as we saw what befell Wallace and his cries for ITSA FREEDOM.

“I only said I wasn’t renewing my Ahrma membership for 2012”

The same fate took Joan of Arc to her death with burning at the stake in Rouen and then when she
was dead the British burnt her body twice more until she was truly cremated and then threw her
ashes in the Seine.

With modern welding skills where they are today SG elected the “sawing in two” even after seeing
the pictures

“You can’t be serious ?”

” YOU REALLY can’t be serious !!”

SG gets her tubes tied

As if by magic a Fed-Ex van turned up with the Magicals so perfect timing to move on another stage
with shocks and the revamped back wheel. Other predicitions were also correct with nothing from
USPS, (it was Monday !) so today I’m expecting the fender brace and then the arse end can be
completed.

Further along the delivery chain I’m expecting the arrival of bars and shifter about Thursday and a
few ancillary bits. Hoping for the front mudguard, brace and number board sometime this week, then
its the motor parts in about another week or so and the final painting and build.

The new Magicals are 1″ longer than the Showas they replace and my top mount was just a couple
of thou bigger than their hole so a little grinding to get the fit. The original YAM OEM shock washers
look a little too big on the top ends so a quick visit to ACE to see if they have anything that would do.

New Magical duplex shocks go on

The revamped back wheel pops in but the chain isn’t ready yet as it needs a good clean before fitting.
While I’m grinding my finger away UPS drop off the new front number board and Gas Gas front
mudguard mounting bracket. The front mudguard is coming direct from Gas Gas USA so not sure
when that will be here.

Back to the chain and the wire brush to remove hardened grease and other nasties. They usually
clean up well and then a “little” pre season lube and hear the pleasant noise as the back wheel is
rotated. Going back in time the chain was a trials rider’s prime maintenance item especially when I
was a boy. Regular oiling, the three weekly boil up in goop, periodic link removal and so on. All bikes
had chain oilers and the would drip heavy oils on the chain throughout your happy Sunday. The mess
that they made was quite alarming with black spots all over the back wheel inside the mudguard and
as speed increased down country lanes a fair deal of the stuff was all up the back of your leg and
barbour jacket ! Along comes the aerosol can and various consistenceies of greasey sticky oils go
on our driving force. While they may prevent water from getting in the rollers they are best described
as those old sticky fly traps that everbody used years ago stuck up on kitchen ceilings with a curly 2′
streamer covered in dead bodies, they don’t collect flies but all the grit and dust of the modern day
American trial sticks to them like the proverbial to the blanket !  Keep it lubed but wipe off the excess
and unless you are riding in wet or muddy conditions I would suggest a drier chain with less oil and grease will actually last longer…… and always carry a spare connecting link in your “go pack”.

Wednesday morning and the chain is restored and ready. Next decision, time for a new tensioner
block, and I bought a bunch of these “block and guide” style ones which I have been using on the
Enfield and the Cub. They require a bit of “adjustment to fit” on the Yamaha curved tensioner unit
but it looks good when mounted. Next problem of the morning, with the new shocks mounted the
swinging arm is at the bottom of its travel and with the sidestand mounted on the forward frame this
means the tensioner is limited in its downward movement. Solution: more work for Shade and the
Makita to saw off the thick bracket !……. which means taking off the left side footrest to get at the
offending bump.

After cutting and shaping, the block is on

This was a poor design on the TY250A and now it has to go

An early arrival of the UPS truck and its the Gas Gas fender/mudguard which must weigh all of 4ozs.
Next problem how to make the Gas Gas bracket fit the TY forks. The bracket slots through the fender
so any bending can be hidden under the fender. The Gas Gas front brake hose retainer will need to
be filed off and maybe the holes need to be slotted and some filing on the edges to clear the TY
wipers.

The New Gas Gas fender…….. now make it fit !

Unknown bracket on left, Gas Gas on right which slides through the
fender and has screwed holes in center

Third, an unexpected problem, the new highly polished number board from Lewisport is about 1″
shorter than the previous one I have on the Cub and looks a bit strange to say the least. Remedy :
use the old one from SG and repaint to match the new livery.

I ordered what I thought was “Narrower” being across the forks, not
shorter between top and bottom yoke

USPS delivered some of the ancillary stuff but the rear fender bracket is still wandering aimlessly
through the lower 48. Priority with tracking is the only way!! Another package (with tracking) went to
Colorado Springs which I thought was a bit strange especially as the update said “Out for Delivery”
…… thats a 300 mile trip ! …… no doubt it will now go to Denver and then me.

Thursday and after a 4.5 hour school run I’m a bit tired so not much going on this morning and I have
another 3.5 hour run this afternoon, but then a free day tomorrow ! That being said I see the shifter
and handlebars are out for delivery so some progress at least up the front end can be scheduled.

No sooner had I typed these comments and UPS turns up with bars and shifter……… and while I was
out driving Fed-Ex delivered the missing rear fender brace so a ton of work to do tomorrow.

TONY DOWN

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  • 3/17/2012 7:36 AM Scott wrote:
    It,s shaping up and looking good Tony.I,m curious to know how well those Magical shocks perform.I need a pair for my plonker and was leaning towards a set of Betors from speed and sport because they look good and are not too expensive.
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SIFTING ASHES

SIFTING ASHES

SIFTING ASHES

With Superglitz reborn like Phoenix from the ashes I seem to be in a “gestation” period while things
get shipped. No problem but I’m getting a little impatient to get it all back together and get some light
testing done.

When the barrel and head get back its not a slam dunk back on 5 minutes as both will be repainted in
the new livery, then fins edge cut and polished…… not going to all this expense and rushing the last
crucial stages. However in the interim I should have everything else done … YIPEEE !!

Just had a quick look at the back wheel, a bit of tire creep, you really can’t trust that Andrews man, and
it needs turning as the leading edges are begining to round off. Sprocket could be Ok but looks like its
just starting to hook. I believe (now I’ve been through the boxes) I have a new chain and a new 12T
front cog so I’m thinking with all this expense may as well change it all for the new season………. and
a new tensioner block to finish the job off.

The valve shows the “creep” which is why we take those nuts off and
throw them in the bin !

Leading edges just rounding off so time to turn the tire, worth quite a few
points in mud, tree roots, and wet rocks

You may remember I’d started work on the rear brake and as always take the whole thing apart, give
it a thorough cleaning, clean up the pivot arm and regrease, clean the faces of the shoes where they
touch the cam and lightly grease as well. None of this has been looked at in nearly 4 years!

 

The magnesium has gone off in 4 years

Inside all clean and lightly greased

Back to its former glory

A morning of wheel cleaning, tire turning and getting it back to spec before the other parts arrive and
the Sawing the lady in two routine ! I clearly selected a very good looking wheel when I built this baby,
rim, spokes, hub, all in excellent condition, so tire off, clean the rim and remove those ugly sprocket
tab washers…… we will run without this time with some stainless allens. Through the dead petrol
wash and then a soap and hot water follow up.

These tab washers are forever collecting mud and grass

Good looking wheel

With a new rim tape stuck in place and suitable holes cut its time to refit the tire the other way round
and the Michelin behaves nicely as always. Cleaned sprocket refitted with allens and already to climb
aboard SG when the shocks arrive.

V Nice !

Anytime you have the bike in pieces always worthwhile cleaning the axle to remove all the hardened
grease which if not removed will sooner or later stick like glue in the hub and you will end up using
drifts and other tools to get that spindle out of the hub or the spacer. When I refit, I lightly smear the
shaft with a little grease and this makes life so much easier the next time it comes out.

All spruced up and raring to go

…….. and then a FED-EX truck pulled up outside with my new Magical shocks……… the build continues
tomorrow

TONY DOWN

 

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  • 3/15/2012 3:25 AM Bill wrote:
    Tony,I always enjoy reading your blog. Thanks for for your efforts. I bought a tube of Autosolve,How do you apply it? I am working on my rear hub also,but can’t get it to shine like yours does. How do you do???? Thanks, Bill
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    1. 3/16/2012 4:48 AM Tony wrote:
      Bill,
      I trust you have removed Mister Yamahas paint ? Once you exxpose the bare magnesium you can fine sand then apply a fingertips worth of Autosol and generous lumps of elbow grease and as my drill Sgt said “It will shine !”
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BAR HOPPING

BAR HOPPING


BAR HOPPING

Not a saga of liquid refreshment and wild, wild women more along the lines of musical handlebars.
Having sourced a set of 6″ lift black bars for the SG its now time to move the other sets around for a
unified finish to the 2012 projects.

Superglitz gets the 6″ blacks and then the 6 inchers currently on her will move to the wife’s baby
TY125 Yam which has some slightly lower ones which I think are 5″ ?…….. These in turn will move
over to the Gun Carriage Enfield allowing me to raise the Marzocchis in the Enfield clamps. The
lo-rise Hebo’s, currently on the Enfield, can now be an emergency travelling spare set.

Just like my old “shoot” pub bar at Romsey  in Hampshire

No Excuse Cub retains the Hi-lift unbraced,slightly wider Renthals and everybody gets a new set of
grips. Dominos for SG, in white/black and new Dohertys for the rest.

So a three bike attack begins removing cables from Glitzie as these will soon be recolored in yellow,
levers and bars off too. The Gun Carriage needs the forks raised in the clamps, the flatish Hebo bars
go and while I’m at it I’ll hack a couple of inches off the front mudguard.

A herd of Colorado Longhorns

The work on the Enfield is easy for once and I’m not forced to remove the wheel to adjust the forks,
must be my lucky day? However it does have a ton of things on the bars with decompressors advance
retard and who knows what.

Repositioned fork legs in the Saracen billet yokes

A couple of inches shorter for the more modern look

In the corner the baby TY gets stripped of bars and I have allen keys everywhere and sets of spanners
at each bedside as the surgery continues. With bars loosened or removed they look like “cafe racers”
or some of the local sheep.

Cafe racer Enfield and a “sheepish looking” baby TY

The bars go back on, levers adjusted, and throttles all checked and now the grips. The Stanley knife
removes grubby old Renthal grips and all and sundry take on new rubber and glue.

6 inchers on the TY125 and new Dohertys too

  All work now finished on the Enfield to my total satisfaction, one down, three to go ! A chainguard for
the TY 125 to be fitted along with a much better condition rear wheel and then the carb cleaning ritual
and she will be ready for the Canadian adventure.

With all the mods done the Enfield scales in at 264 lbs. When they left the
factory in trials trim the owner’s manual says 309 lbs

The new front end

I like it !

Ready for 2012

TONY DOWN

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PROJECT SG

PROJECT SG

PROJECT SG

Parts up the wazoo en-route

Not a great deal that can be done this weekend as I’m in the “parts waiting” phase again ! No matter
how you try and plan it the postal system will end up as a “weekend + 2days” affair and that part you
were so hoping for to arrive on Saturday won’t be here until next Tuesday…… as nothing, but nothing,
gets dlivered on Mondays……..and the most worrying of all is my engine is 3 days late at its destination
as I elected the cheaper option of parcel post and didn’t put a tracking label on it either….. what was I thinking ??

“Sent your engine parcel post without tracking ? ……… Good luck finding
that !”       ” Cheers”

The NEW Magical rear shocks seem unlikely to be here this weekend but maybe the fender brace will
make it. The NEW black handlebars and shifter are en-route as is the NEW Gas Gas front fender and
bracket.

Things I can do for Friday/Saturday; …… and in no particular order, finish the NEW alloy oil pump plate.
Find that elusive black piece of rubber (ACE had some but in an awful primer brown color… YUK !)
and shape and rivet onto repainted lower rear fender and fit. Fit repolished Majesty chainguard. Refit repolished flywheel cover. Do the “Saw the Lady in Two” trick on the rear frame loop. Maybe fit the rear
fender, or not, depending on arrival of brace. Finish cleaning the back wheel, chain and other
ancillaries.

The “sawing the lady in two trick” with the TY frame

“NO Shadetree ! the other way round !!” 

Keeping up on the ITSA front we now have our permit for Turkey Rock and my other task today is get
the permit app in for the Dolores Trial and Vintage Trials School for August. Further consultation with
maps and new ITSA West member Walt (who works for CDOT) shows the piece of land I thought
belonged to CDOT is actually Dolores Town property ! Stumped at the crease on this one As Tom the
man in charge is out of the office until Monday.

Found some rubber in the shape of body armor that came out of the BMW jacket. After several mental
fittings its cut out, drilled and rivetted with suitable cuts to let the pipe through. I think it will work but we
will have to wait until I mount the new exhaust.

The piece of scrap alloy eventually turned out well and is now in the polish phase before being fitted.
It may or may not get a Yam decal on it.

Skill set improving with Makita and file

First sanding

First dose of polish

A phone call makes my day and the barrel and head have made it to their destination despite the
“FRAGILE” stamping on the box which is apparently like a red flag to the bull, postal worker wise, and
arrived well abused. What a relief ! With any luck I might have it back by the end of the month.

Saturday then, some light assembly, before a day on the slopes tomorrow. With the new black bars
coming this will allow me to color co-ordinate the cables in bright yellow and be a good contrast to all
the other fittings.

I ran across a very interesting “object on ebay”, none other than a flat sided OKO carb ? I have always
used Mikuni VM 26 Carbs purchased from Bob Ginder at BJ Racing for all my Yamahas and I find
them easy to tune and have always worked well for me. On the Cub I’ve been using the Dellorto which
does seem to be an almost faultless carb and I was considering fitting one on SG as Majesty say its
a worthwhile mod, but in $ its about $245 plus shipping wheras the OKO is between $120-145 with
FREE shipping !


A great carb, the Dellorto but pricey at $245 +shipping

The flat slide OKO

Saturday morning and parts start going back on with the new oil pump cover, the lower rear mudguard
with its exhaust flap and the Majesty chain guard. Just a couple of other items I need to do but good to
see her taking shape.

Oil pump cover on but needs a fair bit of “elbow grease” and the autosol

Repainted lower mudguard in place with new exhaust rubber

Majesty chainguard completes the morning’s work

TONY DOWN

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OUT OF THE LOO

OUT OF THE LOO

OUT OF THE LOO



The joys of a workshop without a heater in Colorado, just wait till I get
my IRS refund !

Well these temperatures are really causing me some grief !  This morning its 4F and certainly feels
like it and the forecast is not to even make freezing point throughout the day. I’m trying to paint my
lower fender for Superglitz, a simple task one would say, it was already painted in white so a pretty
good base coat so just clean and add the required color. Simple you say ?

Can’t understand why this paint won’t stick

Of course life isn’t like that and I’m painting outside the spec for the paint. Today then, strip my
previous disaster and try again.

“OK, smarty pants what are you going to do to make a difference this time?”

“Well Jose, as I own a RV park with hot showers etc I’m going to use the Ladies Restroom/Loo and
Shower facilities as my paint bay !”

When entering said room the light switch automatically switches on the heater fans making the
room pretty toastie for anyone taking a shower. As the owner I know this room can get pretty warm as
many of our guests seem unable to grasp the complexity of the “on/off” switch and leave the bloody
thing on full time.

The Office floor is cleaned of the debris left by the thawing Superglitz, stripper is applied to the plastic
and the wait begins once more. Round 1 done, second coat of stripper on and now time for other
tasks. Third coat on and leave overnight. Finally back to black and rubber removed ready for some
paint.

The ladies Loo is prepped as the paint bay and the battle commences once more.

A tentative Renoir readies the rattlecan and palate

Fingers crossed……..

So a couple of days to dry, harden and set before I refit and in the meantime I need to find a suitable
piece of rubber to replace the worn out burnt original where the pipe goes through. Next on the menu
time to get some work done on the back wheel and repolish the mag brake plate. While wandering,
the now clean, workshop the “eye” came across a set of new gold rims ? Can’t remember what I was
going to use them for but ………. maybe, just maybe, they would finish this job off if I can run to it.

Gold rims ?  food for thought

Serious polishing required

New cover plate to make to replace the oil pump cover which is already selling on the bay.The shocks
should have left the UK today so I live in hope they will be here within the week. Found a TY250D style
rear brace which is what I used on the previous Majesty so I can now take the hacksaw to the frame
and cut off the rear loop with “that” offset mudguard mounting point which just looks wrong.

Rear Loop removed on my previous Majesty, you can also see how the
TY250A kickstand can hit the sprocket.

Today’s mission find some alloy and a bit of rubber for the lower mudguard. Still looking for a new set
of bars in black and some black petrol pipe tubing. Still on the waiting/arrival list:

Engine  Barrel and Head

Rear Shocks

Bars

Front Mudguard in yellow

Front Mudguard  brace

Front Number board

Rear Brace

Folding tip Shifter

Special order decals

Alloy found, a bit more skillful today with the saw, so the shape is hacked out and filing can be done
to finish the job off and then drilling and final polishing. Rubber still proving elusive, but the search
continues!

Meanwhile a Gas Gas fender is sourced from Adrian Lewis along with the smaller version of the No
Excuse Cub’s front plate…… slowly coming together now…… just need to find those black bars and I’ll
be well pleased.

Over on the ebay the last two items are coming under the hammer tonight and like all things ebay you
can never tell, for example when I built Glitz and Superglitz from the 30+ yamahas I had I used a couple
of cable guides. One went around the wiper and the other on the upper fork leg just under the yoke,
anyhoo I put them on ebay at $10.99

SOLD for $ 37.00 !!! how can that be ???

So tonight we have the showchrome exhaust which at last has a bid, and the SM tank/seat unit signed
by Mick Andrews. The last time I sold one of these units it was for a TY175 and the bottom of the tank
got cracked and was therefore pretty useless…….. it sold for $350 and went off to France !! So what then
will happen to a Grade A unit + signature ? Currently it has a bid at the opening price of $249.99

SOLD for  $184.87  ……. perhaps worth $250 ?

SOLD for $273.88 I thought it would be close to $400 with that sig

Today I found the 6″ lift Black Bars……..Hooray! but at the same time my engine is missing ???
I should have paid the extra, sent it Priority and paid for tracking…… but I didn’t and its now 3 days
overdue at its destination. Still the post is a mystery all round as a letter from inside the lower 48 sent
last Saturday is not here but the Domino grips from the UK made it in 4 days.

Back to waiting…….. but its getting warmer

TONY DOWN

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OUT OF THE BLUE

OUT OF THE BLUE


OUT OF THE BLUE

Once again I wait ! “Out of the Blue” sounds a little military and is reminiscent of my flying days and
sitting at the end of the runway on Alert. Well today out of the blue refers to the 4 big travelling boxes
that accompany the trials bikes on their trans american journies. The Question is “what is in them, do
I need them, or is there a pile of stuff to sell or junk ??”

What secrets do those blue boxes hold ?

These and many other questions can now be answered as another weekend looms and I can brave
the workshop cold to investigate.

This may take some time

An afternoon of sifting, sorting, scrapping and getting rid of the “magpie” that refuses to junk  parts
when they are clearly done……. I must have had 20+ used sparking plugs in amongst the boxes and
none of those are ever going back in an engine so why keep them ?

Boxes rearranged and up on the shelves where I can see whats what and then come May and our
first event of the year I can methodically load what I need for the trek up to Canada and Outlaw Dave’s
25th Outlaw Trial.

Let the dog see the rabbit

With everything boxed up to my satisfaction time to get on with today’s project which has to be that
swinging arm. The new bits (which I now know which box they are in)  are readied for action and
destruction of the fiber bushings begins.

New bushings and shims at the ready

While I’m doing this I can’t help but feel something is wrong here ? The sharp little tool breaks off
chunk after chunk of fiber and finally both sides are free and clear…….. then it dawns on me …… the
center section is missing!!!!!!

Lots of soul searching,  “could I have assembled it like this ?” etc, etc,…….. but then I get to thinking
and the only explanation has to be that while it was being “easy outted” for the grease nipple I can only
surmise that it fell out on their workshop floor ! No matter, I know I have some spares…….

TY250 in foreground,  TY175 behind

As we can see the TY250 unit has perforations in it to allow the grease to get in between the pivot
bolt and the carrier. Strange that the TY175 doesn’t have the same system and must rely on there
being enough grease on assembly and that the owner will religiously grease the unit about twice a
year. While the 250 unit has those holes to let the grease in, if there isn’t any and water and mud have
ingressed the unit then it is easy to see why they can rust and lock up. The unit is readied for action
and fitted.

New bushings in, shims in the cup

Footrest hangers are straightened, units cleaned and reassembled and after the choice of swinging
arm bolt length the whole bionic assembly slots into place with a little persuasion.

Cleaned up and ready to go

“Swing low……. sweet charr…….iot”

C’mon new shocks

So with the swinging bionic arm in place with it’s new grease nipple, bushings and shims, not
forgetting a new carrier time to get an expert opinion from none other than the Bionic Woman,
Lindsay Wagner.

“Hows that feel for a bionic swinging arm ?”

TONY DOWN

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