THE OUTLAW DAY 1

THE OUTLAW DAY 1

THE OUTLAW DAY 1



Not today, the oil leak wins

Bikes are duly unloaded, tires set, refuelled and ready for action. Sadly the JB weld on the Cub oil
line is weeping and with a 25 mile loop this would not be prudent to have it part company in the back
of beyond.

Steve Fracey was due to ride the Superglitz to retain his unbeaten record in the event but even after a
quick ride on the Enfield says he thinks humping the beast round would be a bit hard. I’m dressed for
Cub riding but now have the untried Superglitz to get used to which I last rode back in 2006.

The Outlaw and Blackcat finally meet

Outlaw Dave briefs us on the day, 31 sections, 40km run, a few hazards and steep downhills. The
entry seems to favor the Yam breed (no wonder there is a Yam class tomorrow) a couple of Reflex
Hondas, a few Bults and a Fantic and an Ossa Gripper thing in Orange …….. off we go !

Seems not only have I forgotten a lot about this trials game riding wise but my section memory for
reporting is also failing. However, I can remember some of them and there are quite a few pieces of evidence, courtesy Dave, to jog the brain cells…… be it The Good, The Bad, and in some cases The Downright Ugly !

I can remember the first two sections and indeed thought No 1 was a fairly simple affair up the hill,
cross sides and set up for a minor log crossing just before the exit. Stayed on the planned line and it
all worked as advertised….. but I noticed in Dave’s Gallery it was not all quite so simple for everybody.

Nice easy clean on Section 1

Problems on 1

Maybe not as easy as I thought ? 

Section 2, which I believe was called Rock Garden was taking a fair number of marks and had it been
no stop scoring would have taken a lot more as many transformed classic 5’s into working man’s 3’s.
Entry over a couple of rocks and stay left to the blue ribbon to get behind a stump and then choices of
either straight on over some rolly rocks or out to the red ribbon for a slightly longer run with a recovery
area before a big tree and the exit. Again the plan worked and no unexpected surprises.

Another nice clean on 2

The next two were classic uphills and had they been part of the loop they would have been ridden
without much thought in either second or third but now as they are sections I can’t make up my mind
on gearing. Back in the day in UK there would never have been a question and second was always
the way to go for momentum. In dry conditions especially in the US we hardly ever see a decent hill
and 99% of sections are ridden in first as there is never any mud either!      …….. of course I make an
error of judgement and use the wrong gear, not enough speed, etc, etc. and pay the penalties of a 5
and a 3.

Wrong gear, wrong speed

Memory fails me here, I can remember the sections but not the order, very much a mixed bag at this
stage, some nice rides mixed with some shambolic attempts. However some stand out  with one,
number unknown, being an uphill round the bush game all the way back down into a fairly level tightish
left turn before lining up on a long grassy climb onto a solid rock and onward to the exit. Not too bad on
this one and should have escaped with a dab but needed another to stay in bounds at the very top.
Good friend Steve Richardson was going well until the big rock when it went nearly vertical on him and
he was forced to bail out.

Round the first uphill now down to the turn and back up

Steve Richardson launches his Apollo TY into orbit

At this stage I’m about to meet my “Waterloo” ! and this comes in the shape of a double section which
I easily clean the first part of weaving between some gnarly rocks. Part II should not really have
presented any problems but the results show otherwise. Mark shows the line over the only hazard in
the section which is a pile of logs with a drop off to the downhill exit.

Mark perfectly on line for the clean

Not 100% sure what I did wrong ?   maybe too fast over the log ?   maybe landed with front brake
applied? maybe marginally off line and paniced ? Well, what ever the reason the result was the same
a classic A OVER T ! …….and it hurt !!  Somehow the SM bear claw footrest bit me in the knee, I landed
chest and head first….. always wear a helmet.

My God ! he’s dropped his charger M’Lord

A Sammy Miller footpeg bite !

The loop riding was fast and furious, some big hills up and down, and a lot of very narrow cliff edge
tracks dotted with rocks, made me think of Scotland without the black mud and very soon I was at
home and thoroughly enjoying myself. Sections came and went, results were either good or awful but
I did feel as though I was improving and think I only dropped a couple in the last 8 sections.

This log crossing was I think the “Outlaw Gimmee” although the next one was definitely harder and
perhaps after my earlier misadventure I was somewhat lucky to stall the motor feet up !

Nice easy clean through the log crossings

Another “4 faults” at Beecher’s Brook for someone

The way home had a nice double with a log between two trees, and then a pile of rocks into the down
hill changeover before a very steep uphill adverse, I litterally flew through the ends in a near vertical
wheelie… a pic of this one would have been great, but a double clean was good.

Next double was an uphill twister in loose shale pebbles and dirt and I nearly made a cardinal error
of going the wrong way at the changeover needing a realignment prod.  Almost back to the start area
and a full downhill for a change for another clean. An uphill turning twister was good until the very end
when I double prodded to stay in bounds.

The last two were the Birdbath, aptly named, for an easy clean and then a finishing confidence boost
at the start area which by comparison to the rest was another “gimmee”. Overall a very enjoyable day
and had I been in reasonable bike fitness I think I would have finished on about 20-25 for the day.

TONY DOWN

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2 COUNTRIES, 5 STATES, 6 DOGS AND A CAT

2 COUNTRIES, 5 STATES, 6 DOGS AND A CAT

2 COUNTRIES, 5 STATES, 6 DOGS AND A CAT

” The wheels on the bus go round and round, round and round……”


Wednesday 16th May 2012 the mission gets underway and we leave only 2 hours later than the
ambitious start time. With major requests from catering and galley staff today means at least a 600
miler if we are to get a “wine tasting” in somewhere up country.

Usual run across into Utah, take US6 through the hills and come down the other side to join I15
northbound and a 50 mile stretch of roadworks leading up to Salt Lake City. After two years of this its
still going on and not much better in my opinion.

Uphill out of Price

Onward and northward, although signs say west we cross into Idaho and 84 is actually a pleasure
to drive on with a good surface and hardly any bumps. Ideal plan would be to make Boise as the
nightstop but the team have had enough and we stop with 650 miles gone. On arrival the dogs go
into mega bark mode as they can see a cat tethered to another RV. The late night walk is equally fun
as Luna, our cat, makes good her escape via tunnel Harry and when Brenda returns with the 6 ship
Luna is under the bus !! I don’t think she wanted to go anywhere just proving a point.

Thursday and Brenda has located the “perfect stop” in the town of Richland WA which seems to have everything we need, overnight parking for the Safari, wine tasting, cheeses, and restaurant and even
a live band ! According to Miss Garmin, our faithful route advisor, this will leave us 280 miles to go on
Friday which looks like an early afternoon arrival up in Summerland BC.

But first a 330 mile drive crossing over into Oregon with its dumb road signs and other quaint little
customs!! The drive is quite beautiful and all is well until refuelling when I’m reminded that it is
ILLEGAL to refuel without an attendant starting the pump ! Well never mind the show moves on and
the camera catches the “dumb” signs.

Speedo or Odometer check ?????

Hunter’s paradise !

I guess several people have tried it ?

Fantastic views and great roads

We now move into Pacific time zone so we will be at the winery one hour earlier than planned so
Brenda is very happy. A couple of beers on arrival and more dog walking and I notice a trailer tire is
going down !! More on this later.

Let the tasting begin………

A pleasant tasting of what’s on offer and then a second helping of what we liked just to be sure. The
wine is pretty good and has its own character from what we now know to be the USA’s second
biggest wine producing region.

The team make our selections

The food is equally delicious

Nice gardens, good food, on a very warm day sitting on a patio with all the other yuppies….. what
could be nicer ?

Relaxing with another bottle

For a few bottles more

Up very early and wehave found a gas station within 0.2 mile, full air up and a 5 mile jaunt around the backstreets with Miss Garmin to BIG O Tires who supplied the tire and are open at 7 a.m. Tire fixed in
no time the mission continues.

Freeways and civilization behind us its single track to the border through farmland vineyards and now
a mass of fruit trees. One last refuelling of all liquids and border here we come.

The border cometh

It would seem that the US must have pissed off the Canadians with its bizzare Immigration policy and
the Canuks are playing “tit for tat” as the border experience is somewhat strange and deliberately long
winded. Inside the main building a lady takes our passports and an eternity later Brenda is given the
third degree over a nasty little DUI she had way back in 1999 ! She is told in no uncertain terms that
Canadian authorities view this very seriously and TWO DUI’s is an automatic refusal to entry !!

Free to go, and no mention of papers for dogs and cats which should have cost $60 for inspection,
we continue through Canadian wine country which looks like its in boom town with every available
piece of real estate growing grapes……. wineries everywhere, and I mean everywhere, this would be
a tasting without end ! Maybe another year !

“are we nearly there ?”

Only one wrong turn on the way in and Mark, who has been despatched as our guide, catches us
before we get lost in the wilderness. Very soon we are established and the fun begins.

TONY DOWN

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OOOOO, ARRRRRR

OOOOO, ARRRRRR

OOOOO, ARRRRRR

Its testing time for Superglitz, but first time to mix some new fuel with a nicely perfumed racing oil that
for those of you that remember the Manx Norton,  AJS 7R, Matchless G50, comes very, very close to
Castrol R.

R

So whats to be tested ? Well we have built the Fembot Bionic Superglitz from a collection of exotic
parts so now time to see if they work in harmony, and are any better, or a quantum leap forward.

Up front we have the TY Mono forks, fitted with Magical Springs, and the IT/YZ front wheel with EBC
grooved shoes. Not forgetting the Gas Gas fender and brace. Up top Pro Taper bars along with white
black Domino grips.

Her mid section got the full BJ porting treatment and new Boysden reeds and of course the up and
over big bore Majesty WES exhaust.  Also the “never gap” NGK Iridium plug. Downstairs a new Moose
bendy toe shifter. Initially I’ll run with the Mikuni VM 26 working a 150 main and 35 pilot. This will then
swop to the OKO to see if there are any noticeable differences.

Down the back the New longer Magical duplex rear shocks and some more new EBC grooved shoes
and of course the new one piece slimline Majesty style retro tank/seat unit and the yellow bendy
fender.

Time to cast off the fuel lines, power cords and LOX and get this baby up
and running

Looks the part

Time to see

The Heady perfume of “R” drifts in the cooler mountain air this morning as the motor dutifully starts
on 3rd kick once crankcase compression has been restablished. No nasty surprizes with sticking
throttles, unusual metallic engine noises, leaks or other annoyonces.

Suitably warm point beast in safe direction and see if the 4 year inactive clutch will join in the fun or
sulk and drag till the ATF gets warmed up. Again smooth as silk so off I tentatively go. First and most
obvious impression is rider memory bank failure……. hmmmm !  The bike is fine but  the rider needs
some work, balance poor, control handling weak, excessive nerves all combine for a less than stellar
ride. Virtually 2 years off the bike, any bike, so a lot of work to adjust the confidence jet to match all the
new goodies, performance and handling.

All 6’s and 7″s while looking for figure 8’s

Knees MAN knees !! Not enough bend and too close together

Getting better

Two weeks before departure so I must get some saddle time in and knock out those cobwebs and
really see just what this machine will do. Seems I need to change up the pilot jet to improve that off
idle pick up. I really need to get the Mikuni back on song before trying the OKO and then I will have an
accurate comparison.

Time slips by and I did change the pilot but due to the arrival of the Cub frame never got to fire it up
and test it. Today that must be completed, and then just maybe try the OKO. First up get Madam’s
TY125 sorted which is a gas change and standard carb clean. Little beast starts and runs as sweet
as a nut and Brenda takes it for a spin and seems well pleased considering she hasn’t ridden for
two years.

With the Safari all sorted for the trip with liquids and a well deserved wash I can finally get SG out
and see how the pilot jet change worked out.  Answer …… VERY NICE !  Ooodles of power off idle in
any gear…… most impressive, revs cleanly right through the range. Only problem observed was a
fuel leak from tank to carb which looks like its coming from the cheap nasty plastic fuel filter… quick fix coming.

The fix was done, testing got postponed with the mass of other work required on the Cub so the full
saga will have to wait until it gets ridden in action at the Outlaw.

TONY DOWN

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THE IDES OF MAY & THE GRANNY CUB

THE IDES OF MAY & THE GRANNY CUB

THE IDES OF MAY & THE GRANNY CUB



“But you promised it would be ready in time for The Outlaw”

Tuesday May 15 2012, no Mayan calendar for this one, 3 out of 4 bikes prepped and ready to roll,
Safari waiting, rider rusty, enthusiasm high after 2 years off. All eyes on the main road looking for
Brown in the shape of UPS.

Here it comes

Still a lot to do and many things left on various back burners. Biggest regret at this stage is a total
lack of practice after all this time off and it will take a miracle of brain power to convince body and mind
that it can still be done !

Lawns mowed, sprinklers on, strimming to go but being within 30 mins of Brown’s arrival perhaps
better to hold the weedwacking until “IT” arrives, certainly don’t want them driving off  with the “Nobody
home routine”

1230 UPS pulls in and the box is unloaded, checked for offending peanuts and is suitably
photographed before any harm comes to it from Shadetree. The tank won’t quite fit as the powder
coating is over the head and seat lug. Ray said spray the exhaust in “hi-heat” but I rather like it in the
“raw”, maybe cerma chrome at a later stage.

Another red cross parcel from California

More superb stuff from Ray

With the lugs de-powdered first fitting is attempted but its too tight and some of my earlier ideas as to
what would go under the tank have to be rethought. The big thick breather pipe and electrics cover are
cut vertically where they go into the frame holes so that they fit flush. The clutch and throttle cable won’t
fit under either as its too tight at the headstock so two “P”type rubber clamps ( rare as RHS in these
parts) are found and used up front.

First fitting…… a bit tight !

But its pretty

P clamps for the cables

Using more of Ray’s technical expertise the headstock drilling is done and then has to be filed !! The
seat mounting is done using Shade’s “seamen’s eye” and works perfectly. So eventually the tank is on,
end of phase one.

Exhaust to go on with Ray’s top mount expansion chamber and Cub men will note this is similar to the
Duncan McDonald’s Armac design unit. With the engine now closer to the main frame the front mount
was extended to an elongated hole. Some light hammering up front and its on but now the SM rear pipe
is difficult ! Try as I might this unit will not clear the right hand rear shock and clearly the mounting point
is different on the SM rear sub frame.

Shade uses the bigger hammer technigue and the SM shortie gets a fair bit of wellie ! An extra stay is required so yet more fabrication as time slips away. Finally it is on and the fatty mudguard gets
reshaped to go round the pipe.

New stay on and clear of the rear shock

Front section in place

With diner on the go only petcock and final adjustment of cables and tubing to do. Again sounds easy
but the undertank crossfeed is critical as it crosses the head. Also the metal rocker feed tube is not
where it needs to be so Shade persuades it but it breaks at the union !!!!!! Only thing for it a splash of
JB weld (sorry) no spares available and running out of time.

A workshop dinner

First fitting of the crossfeed and a little JB weld

With time racing on time to “decal up” and get the old girl loaded. Union Jacks on but somehow don’t
look right against the Candy Apple Green. Stealth and Blackcat will have to do.

Left

Right

Just time to throw it on the scales and then …….

Impressive

Questions ? will it work, did I do a good job with the electrics in the rabbit hole ? …….. can’t resist a
swing and lo. it fires straight up with no hestitation……… amid the smoke itsounds really good so out
it goes ready to be loaded at 2110 on Tuesday night…… we made it Granny !

At 2110 Tuesday night Granny’s Cub makes it outside under her own
steam and is ready to go…..

TONY DOWN

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  • 5/22/2012 12:34 AM trev wrote:
    Hi Tony, the Cub looks fantastic apart from the stealth bomber????(sorry)Even though your not ‘match fit’ i’m sure your gonna have a great time back in the sections.Enjoy the fruits of you labours.
    Reply to this
  • 5/23/2012 7:11 PM Mark wrote:
    Tony, been a pleasure reading your build adventures with the Cub. Up here in Grand Junction and enjoy your page and topics-feet up!
    Reply to this
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THE CORE

THE CORE

THE CORE

Many bites out of the Candy Apple Granny Smith Cub but still aways to go. Every day there are some
forward steps, high hurdles to overcome and a collection of idiots along life’s highway to deal with.
Yesterday was no exception to the rule and indeed I met more than my fair share !

Those remembering ramblings from the blog will recall that when Ray sent the oil tank it was
missing the fiber washer on the drain plug. Also having switched to ATF for all the Cub’s liquid needs
several of the drain or level plugs have decided to weep. A couple of dollars more, and a selection of
those red fiber washers will soon fix all those leaks and weeps and of course the Royal Oilfield  just
eats them for breakfast. Not so easy Cronstein !! Everywhere I have been in 3 days of looking either
hasn’t got a clue what I’m talking about, has never heard of them, doesn’t use them…. all quite
unbelieveable and I’m beginning to think perhaps its me ?

I have asked, using a variety of scripts in case there is a language barrier,  “Oil drain plug washers ?”
“Fiber washers ?”    “red fiber washers ?”  so nothing has been forthcoming and no better on finding
oil pipes. The last classic was
” Good morning I’m looking for some 1/8 ID flexible oil pipe ?”
” You want a dipstick ???”
“No DIPSTICK, I want some oil pipe ”
” What’s it for ?”
“Well surprisingly oil ! .. it carries the oil from the oil tank to the engine and back again”

In case i was really going out of my mind I checked on ebay and yes, they DO EXIST, and I’m not
going mental.

Fiber washers I believe

Friday and time to switch horses for awhile and check out the Safari transport as I really don’t want
any hassle in that department. First changeover from shore power gas (LP) to internal, check the
generator fires up and then onto the main motor topping up oil and coolant. Now the tires which were
new last summer, along with batteries, and the final will it won’t it ? ……. but it fires up. Just some
oddball items to fix and I should be good.

Back in the Tiger’s Den the Arabic puzzle ring game continues trying to fit the PVL top coil in a hole
that is marginally too small. After many attempts the rogue item is in place and hopefully will allow the
tank to fit over the top. I had a 2″ Core to play with !

2″ to play with under the new tank

It’s very, very close !

Bolted in and I have SPARKS

With the coil in place time to button up with all the breathers and oil pipes. Strange stuff this 4 stroke
business. Rocker pipes on and a run to the oil tank, outlet and inlets for the oil and a fiber washer was
found but I will be ordering the big set.

The Armac breather goes on and same style protective covering for the ignition wires which were
treated to some aquarium silicone before being clamped in place. Only one more vent pipe to fit and
then I’m as far as I can go until tank and exhaust arrive on Tuesday. A quick review of where I was last
Sunday and where I am at close of play Saturday.



Sunday 5/6/12  the parts arrive from powder coating

Saturday 5/12/12

….. and now we wait for UPS

Meanwhile over in CA the tank continues through the Master’s fabrication from sheets of alloy to yet
another work of art. With this redesigned narrower stealth tank holding 3/4 gallon it is necessary to
have a cross flow system to keep the burner alight.

Crossfeed pipes ready for welding

The “naughty” male and female bits get welded on

The Stealth tank is nearly complete

Now where is it ?

According to Homeland Security who have inside intell it left CA on Thursday and was last seen in UT
at Salt Lake City. Further intell suggests it may leave there on Monday in the small hours and make it
to Grand Junction, CO by Monday night and then under the cover of darkness slip out of there for
Durango and onward to Dolores with a 1200 ETA .

TONY DOWN

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A GRANNY SMITH CUB

A GRANNY SMITH CUB

A GRANNY SMITH CUB

Thursday, Tuesday’s frustration behind me a pretty good construction Wednesday, lots of problems
but remedies coming to the fore so resolution seems to be at hand. The issues with the DID chain
were overcome for testing purposes by putting the old one back on but it is too worn to really use in competition unless I’m forced to for Dave’s Outlaw.

Next problem the left side oil tank sits promblematically close to the chainguard and could get it’s
bottom dinged by an upward travelling swinging arm. Well most Miller products are too high so I
lowered the whole shooting match about 1.5″ and after learning a new trick from Ray was able to
fabricate a recessed bolt hole in the ally …… very clever when you know how!

Chainguard lowered

Moving on, the carb sits nicely to the left of the top tube but lines up perfectly with the left side oil tank. Choices, either find an offset inlet manifold, get Ray to make one, or a trip to Autozone for some bent
radiator hose in the correct diameter…… or use an offset UNI podded carb filter…… or any combination
of all of the above.

Problemee !

……..arrive at Autozone with 15 mins to complete this seemingly simple task !

“Good afternoon” says the customer   “I’m looking for some radiator hose in this diameter, ….. don’t
ask what car it is for as it isn’t……. I just need a piece with a 30-45 degree bend”

“Huuh !” says the helpful assistant

…… off she goes and actually comes back with a piece that looks like it might do

“Do you have a micrometer ?” asks the customer

“What’s a micro meter ?”

“No the word is Micrometer, and its a tool for measuring (very acurately) inside and outside diameters
of things”

“Never heard of it, but I got a tape measure”

” OK this will do…… how much is it ?”

Assistant  types in some numbers and announces     “$52.99”

Customer looks at screen……. “It says BRAKE HOSE !”     “It is not a brake hose”

Requests for a Manager are fruitless and she keeps typing in the same number with the same results
until the now impatient and agitated customer sees that she is using the manufacturer’s part number
and not the barcode ! With the correct info it comes up…… Radiator hose      $10.99

Yes, it IS a radiator hose !

Much cutting, shaping, wiggling and jiggling and the carb and cleaner are now clear, upright and on
the other side with no fouling of the throttle cable. Not saying this is the final solution, might go back to
the left side run with an angled UNI podded filter if I can find one…… and Ray says he will make some
stubs to get it correct from the engineering aspects.

The first cut

Clear to the right side

Upright as well

The rest of the morning is spent cutting and shaping the rear mudguard. Other “first looks” at where
to fit the top coil and a plan B if that won’t work. Amid all the thoughts my Blacksmith neighbour turns
up and after a chat they have a dremel thingey on an air line which I can use to remove some powder
coating from inside the top frame to get a grounding for the coil if it will go in there.

Will this work ?

The top coil project is left but semi ready if I have enough room and attention switched to the back
mudguard which is drilled and fitted top and bottom. With that done the old SM brake pedal is mounted
and adjusted.

The big fatty mudguard goes on

The lower mounting brackets were powdered

Rear anchor works

That wraps up Thursday, so on the remaining list to do:

Fit coil and kill switch wiring.

Fit breather pipe unit.

Fit oil lines and rocker tubes

Velcro seat cover.

New plug and check for sparks

Meanwhile the tank and exhaust left CA and are scheduled for a Tuesday arrival and we are leaving at Sparrows on Wednesday morning. The snail cams are still in transit along with the RK chain. Will I be
able to finish and load by Tuesday night ?……. or will it get left at home and debut at Bull Hollow ?

TONY DOWN

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LITTLE GREEN APPLES

LITTLE GREEN APPLES


LITTLE GREEN APPLES

Saturday is here, and I’m up at the butt crack of dawn ready to get going. The way I see the day going
will be a mixture of gardening tasks combined with last minute prep in the workshop getting ready for
the frame and associated parts.

There is some method in my madness as I must get the routine chores out of the way today to get an uninterrupted run at the build. Brenda has a day off but is working tomorrow so a “cocktail hour” will be
called after I collect the green machine.

0700 and last coffee and smoke before the mission kicks into gear. First the workshop and finish the
back wheel sprocket, quick hoover, and get the items laid out where I can find them as the build goes
along.

Cub to go !

The cleaning gets done, parts are all located and placed where I can see them and get to them at the appropriate time. A little advanced prep in the form of cutting off those outside bits on the SM bushes
so all is ready for the off.

All laid out ready to use

With parts available this should be easy

4 p.m. and arrive at powder coaters only to be told the giant compressor is still playing up. Abe says
he is off to get some other part and my stuff will be ready at 1 p.m. tomorrow.

Sunday morning, and waiting patiently with crossed fingers, I really want to get going on this one and
have a fair chunk completed by nightfall. News from Ray is good and the tank construction should be completed by tomorrow and if UPS is as good this week I’ll be fitting the tank next weekend.

At around 1100 Abe rings to say there is a nasty black goo coming out of the frame which is in his
oven and do I know what it is ? Well I haven’t a clue so on the phone to Ray……. no idea either so I
rush off up the hill to see it myself…….. Abe tells me the smoke from the oven is not so bad and the
goo is getting less. Still absolutely no idea what’s causing it …….. then we have a thought…….. for any
of you WWII military fans you will no doubt remember what  American General Mc Auliffe said when
he was surrounded at Bastogne during the Battle of the Bulge in 1944 and invited to surrender ?

A one word answer from the General …….. “NUTS !”



The cause of the problem…… Nuts, ….peanuts….. packing peanuts !

 It seems these nice little fellows had managed to worm their way into the seat tube during their trip
from CA, and I hadn’t noticed and niether had Abe. With heat applied at 400 they shrivelled up and then
melted but eventually carbonized on the inside of the tube.

Time is now just after 1200 and Abe says he will finish by 2 and drop the stuff off at my place. With no
paint on anything at this stage and with all the other problems I’m thinking this may be wishful thinking.
I carry on some work on the Superglitz carb and I’m completely amazed when Abe stops by with the
finished product a little after 2 !!

On time delivery of the Green Apples

All bearings, bushings and cups fitted

Usually I like to get the frame complete, add the suspension units and then complete the entire front
end to give some stability, and in this case then fit the engine as it is not part of the frame integrity. All
seems to go well and the bashplate and footpeg hangers all form part of the frame. Nuts and bolts
all loosely assembled (a bit like a Montesa !) and then time to fit the BSA B50 fork yokes.

Legs follow along with the bars and now time to tighten everything up. Next set of problems soon
come to light with the very neat mushroom headed bolts just in front of the footrests. First one, with its
locking nut tightens up normally but I note its warm to the touch. No 2 starts normally but halfway in
it stops ? Now I can neither tighten or loosen the bloody thing and then the allen head rounds out !!

Time for something else so on with front mudguard and then think how to deal with these two bolts.
I can undo one side removing half the frame and the bashplate and then saw it off, or I can go bigger
and bigger on drill bits until I’ve drilled off the head which works and saves about 30 mins. A nice new
metric stainless bolt and its better. May as well replace the other one to match and here I undo it until
I’m past the end of the nut but then it locks solid and predictably the head rounds out again! This time
I have enough room and with a small Makita cutting wheel I can get in without damaging the powder
coating. 9 p.m. and I’ve had enough.

Nightfall in the workshop

Monday and my start is somewhat delayed due to other things. Mission of the morning finish the front
end, then first attempt at the motor, some ancillaries and sort out the footpegs which I had started on
over a beer on Sunday. The pegs each have eleven studs with a mini allen in the top. Predictably the
powder coating has got in a few of these holes so this will not be easy. 5 of the holes cause grief and
the only course of action is to file them level with the rest.

Studs in as far as they will go

Back to level

Stops fitted for the snail cams which are still in global transit

Rubbing block and chainguard on

Front end finished

Time for first fitting of the motor, and it doesn’t want to ! With the spacers in the oil inlet catches on the bashplate bracket. Perhaps in a later design it should be positioned on the outside of the engine
giving a “with” and “without” option.  Well thats as far as I get in the morning operation. Post the school
drive back to it and file out powder coating residue from the engine mounts and remove the spacers.
All the remains is to now remove the rear wheel spacer, fit the back wheel, and check the chain run.

Tuesday morning and let battle commence once more. Chain tensioner fitted, now for the spacer
removal in the rear wheel. That goes in the frame and although tightish on the chain guard clearance
should be workable.

Out with my new 420 chain by DID and on it goes, looks very good with the gold contrast to the green,
but can’t help but think its a little wide ? Up on the bench and its about a fishplate wider than the old
one…….. check against another 420 (too short) RK chain……. this one is the same as mine but too
short but at least I know what I’m looking for. Clean the old one and fit, no problems.

About a fishplate wider !

Some time later try and fit the clutch cable……….. not good !! Patience meter showing on full RED, day
terminated, and will try tomorrow.

Wednesday, time slipping away, need to fit clutch cable, carb and cable, rear brake, footrests and
maybe first attempt at oil tank. Other projects, electrics, rear mudguard, breather pipe, seat pan.

TONY DOWN


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CUBBING

CUBBING

CUBBING

With only two weeks before departure to Canada I have a fair chunk of work to get through to get
everything done. Currently I’m UPS tracking on Ray’s shipment and it still says it is “on time” and has
made it to Grand Junction early this morning. Where it goes next I will no doubt see when I get back
from my morning drive. (Back in) yes, left Durango 0806 “Out for delivery”.. yipee!

The Powder Coating company moved buildings but still say if I get it to them today I can get it back on Saturday. That should give me today, post arrival time to get it to them, and then finish off the engine
prep tomorrow ready for a Sunday start to the rebuild. Only piece still out there in the ether is the snail
cams from Wayne Weedon, which I hope he enlarged for me before they left on 20 April. Just heard
from Wayne that his package has now arrived back in the UK marked unclaimed ?? How the hell
does that happen unless the Post Office fails to leave a “signed for slip ” and then returns it after the
time runs out.

The well travelled snail cams having completed 10,000 miles by snail mail,
try it one more time 

The rebuild itself should not present too many problems and by Wednesday I hope to have it back
together save for the Stealth tank and exhaust which Ray is currently working on. Those two units
should just be pop ons with no fabrication required at this end.

Ray starts construction on the new slimmer stealth tank

Inner section cut, and rolled to fit

Redesigned left side mated up and will be welded on the inside

Smaller and neater, but still retains that distinctive F117 look 

With everything else cleaned, prepped and ready to roll there is only the big rear mudguard to cut and
shape.

Perhaps the hardest task will be putting the SM silent block units back in the front frame and swinging
arm without knocking off too much of the fresh powder coating. Only other thing is where to mount the
top coil on the new frame, but I have some ideas.

Just before mid day UPS rolls in with the delivery and frantic unpacking begins to rush the parts to the Powder Coater. WOW !! fabulous stuff from Ray, work of art material.

The big box of “goodies” arrives

Look what Santa sent me !!

Amid the packing peanuts the frame is hauled out in its two parts and I can see the differences
between the modified standard and SM version. I’m committed to use Ray’s back half as the oil tank
mounts to it, whereas the Miller unit has those lugs and stays removed, the cross brace is located
further back (which incidentally causes lots of mudguard mounting issues) and also the downtubes
are widened by about 1/2 ” to cater for the SA bushes which have an extended inner for some reason?
These will now have to go as bashplate and footrest hangers are geared to the narrower width.

The outer SM bushes must now be cut flush

So the Raymobile frame in two parts, the SM swinging arm, and 3 misc brackets are loaded along
with the footpegs with their 22 studs removed. Abe is there on arrival so all looks good and he is still
confident to finish by Saturday.

Meanwhile back in the (novice) workshop the engine has been Harleyised with fresh cut fins and a
bit of elbow grease. Pipes and cables to be redone today (Friday) and also overcome yesterday’s
“problem of the day” which was the sprocket studs or rather the very last one which immediately
rounded out as soon as the allen wrench touched it ! So having decided on the spacer route the other
bunch were removed ready to refit the rear wheel spacer until the last one…… now the fun begins, and
what thread is it ? It has a metric allen, so much I know, as no American allen comes close to fitting.

The last one….. but now its gone !

Well Shade’s old friend the impact wrench soon dealt with that baby ! so now the spacer can be fitted
and 8 new stainless bigger headed allen bolts used.  Further investigation before refitting shows the
spacer only goes one way as there is a recess for the roll over cup of the brake plate. Good thing that
Shade saw that before bolting up.

Afternoon trip to town for nuts & bolts and a few other essentials. First few places on the list I may as
well have been talking in Esparanto as nobody had a clue what I wanted. Finally a breakthrough and
everything I want, well nearly everything, is located in one store.

Drop by the powder coaters on the way home and their new compressor is causing grief with a blown
gasket letting oil into the coolant system. Usual thing, a $5 gasket and 10 man hours to take everthing
to bits to replace it. Howevere, they still say 4 this afternoon and all should be ready

…….. until then

TONY DOWN

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  • 5/10/2012 4:17 AM Jose Bustamante AC wrote:
    Tony, you didn’t mention what sort of stuff you can get at the Hardware store that might help with the gouging caused by the chain rubbing over the frame.
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MORE NEW GOODIES

MORE NEW GOODIES

MORE NEW GOODIES

Ray works on the prototype “Big Bore” Cub Exhaust

There would seem to be no stopping the Californian fabrication department and here is something I
really like and find quite intriguing.  Over the years many of you will have noted as footrests have got
lighter, wider and more expensive and with the use of cheaper, weaker, and nastier materials that with
the passage of time and use these toys begin to develop a granny droop.

Well not anymore, Master Fabricator Extrordinairre has come up with something that little bit special
and I’ll be privileged to try them out on my Raymobile Cub when I get it all back together.

What normally happens especially with lightweight alloy is the end of the peg that is against the peg
mount gets compressed or the holes in the peg themselves elongate such that when they return to
their normal rest position they now tend to lean out and droop.

Lets have a look at the system in more detail, a simple design which means that as long as you
haven’t broken anything you can adjust as much as you like including a little upward cant if you wish.
A stainless steel angle bracket fits over the peg stop and is secured by two screws at the correct
position. A third screw with locking nut comes through the unit from behind and now as it is adjusted
the stainless plate pushes into contact with the toe of the peg in its level position. When you have the
desired position tighten up the lock nut and the two slide screws and you are done

Ray knows just how much I love polished alloy and his apprentice, John, is mastering the “art” …… so
as a special bonus they polished the footpeg set, and have set about the bash plate ! Of course I
knew he would be polishing the tanks as per the “One Trick Cub” and from the latest progress reports
it looks like the oil tank is nearly finished way ahead of schedule. That will leave the new design tank
and brake pedal and the modified exhaust which will need to go to the powder coater for some
ceramic treatment.

John starts on my bash plate

Glasses on for the heavy duty stuff

What’s this ??

John turns the oil tank into a shaving mirror

Now that sure is pretty !

One Coors Silver Bullet later…… v nice !

 With all these endeavours in California I’d better get my proverbial in gear next week and set about my remaining parts in Colorado. With Superglitz done, it really is No Excuses for the Cub and of course
Brenda’s mini TY 125.

Clean but nothing special

Cables and pipes need a reorg

The engine was whipped onto the bench, washed and cleaned but now needs that bit extra before
being mated up with all this hi-tech out of state stuff. I’m thinking some fin cutting as it was never done
in the past and would give it a sort of “Harleyesque” look. No color changes this time round, just black
and silver with muuucho elbow grease and a splash of Solvol.

The wheels were done and I’m still undecided on spacer or not but leaning towards putting it back in
to keep the chain run as before. I have made a swinging arm protector so that is done and ready. A lot
more demon polishing on the NEW old alloy wide rear guard and another couple of doses on those
B50 forks but that can be done while watching TV as I’m now running out of time.

Wheels up to standard, back sprocket spacer or not ?

 A few busy days of school bus driving so no fiddling with bikes and then a full Sunday of gardening to
get that all up to speed before summer is upon me. Consultation with the Guru who tells me phase 1
is complete and the mainstay pile of goodies will be shipped today, 4/30/12.

From what started as just a Stealth tank has now become a complete modified frame, with tweaked
head, braced top frame, widened front mount, a set of precision spacers, beautiful bash plate, custom
made peg hangers, left side oil tank, seat pan unit and all the associated hardware.

New set of spacers

What the rocks will see

Ray has added a drain plug, upper mounts fix to the frame offset angled
plate under the seat pan

All the brass hardware  suitably “plumber’s taped”



Easy access door to fill

Easy grip filler cap

Top section velcros on

My parts ready to go in front of more of Ray’s fine work on a BSA

Now that’s a lot of work !

First batch now with UPS 4/30/12

TONY DOWN


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