CUB IN A BOX

CUB IN A BOX


CUB IN A BOX

With plate spinning in full flow and Escalante Days Trial taking shape it looks like I might finally get
round to rebuilding my faithful Cub. She has sat in the workshop since about Thanksgiving. A respite
from weeding at last, and as my non stop endeavours continue I can at last see a time frame for a
good bout of uninterrupted spanner wrenching.

A Cub in waiting

For those who have not been reading the blog the situation was the redesigned 2012 edition suffered
from bash plateitis and gave me some very sudden an unexpected “5’s” as I wandered down trial’s
highways and byways!

Also at some stage some nice kind soul knocked my bike over resulting in the cheap nasty Betor rear
shock rod bending. These were replaced by the identical set off the Enfield so that I could ride last
year’s Escalante Day Trials but had to go back on the Enfield for its upcoming sale. Over the winter a
new set of Rockshocks were ordered and duly arrived in 5 days from the UK.

The dead Betor

New custom Rockshocks from John Bull

Meanwhile Ray cut out the offending lower tube from the frame, fabricated some forward engine plates, rebuilt the footrest adjusters, made a bigger hole for the coil to fit in and reshaped the bashplate.
( see Hell’s Kitchen 13 )

First go at the rebuild resulted in disaster with a self inflicted hole in the crankcase but that has been
subsequently beautifully welded by a local expert after a trail of tears through about a dozen welding
and fabrication shops who all told me it was in the too difficult basket.

Ooops !

So thats where we left it……… now read on:

Saturday 29 June and a thunderstorm rolls in, so no section cleaning this afternoon, the Safari gets a
quick look but too wet for rolling around under the engine so into the workshop and first attempt to fit
the motor after refreshing all the oils.

The transfusion is underway

Close but not acceptable

Suffice to say it “nearly fits”…….. one of the bash plate bolts just touches the crankcase so something
has to be done here. Choices are either use a smaller locking nut or reposition and redrill the plate
and bracket to a point where it is well clear. First I’ll cut down the bolt and nut insert and see how that
is and what clearance I have.

2nd attempt

The engine is refitted and all looks good this time around but now I’m informed guests are coming
for drinks so my plans to complete the front end are slim. Better loosely assemble the back end and
try and line up frame, swinging arm and the rear sub frame and get the SA bolt in to stabilise the
show.

Taking shape

Guests arrive, mission terminated, but with the monsoon season nearly upon us and afternoon rain
I should be able to fit bits and pieces slow time during the coming week, not forgetting more section
cutting for the Escalante 2 Day, lawn mowing, work on the Safari and if I ever get round to it time to
swing a leg over Superglitz for this weekend’s 2 Day over in Sipapu NM.

Another lowish achievement day; shade garden lawn strimmed, radiator on Safari blown out and
hosed several times and another major louvrectomy completed on the upper door. Time to put it back
together and test drive.

Back in the workshop and time to add some more parts starting with the footrest hangers, SA nuts
and the freshly reoiled fork legs. Legs in handlebars on, clutch system all connected and back in situ.
Lower fork leg clamps, fork stops and front brake lever and cable back on. Mudguard and front wheel
would have gone on but…….. more guests arrive for drinkies and today its my old favorite Gin & Tonic.

Plans change again as I needed to get the Safari up and running for the Sipapu event this weekend
and I needed to sort out the rear tire on the bus which leaks ever so slightly. I rang the company that
fitted the tires some 2 years ago and they immediately sent somebody out to sort it out at home! What
a fantastic service and totally unexpected. With that done I went and topped up the LP gas and diesel
so I’m ready to load Thursday night.

Not enough time to go section cleaning so a bit more on el Cubo. The front wheel gets changed to
the old wheel from Superglitz but this needs a slight adjustment to the brake arm as it has new
grooved shoes. It gets fitted and the front end is all aligned and tightened up. The back wheel is
added to give some balance.

Close of play 7/2/13

  My game plan for the day never came to fruition as I had planned more section cutting as the primary
mission with a back up of the Cub if the monsoon dropped by. Brenda goes into town for the weekend
shopping so I’m going nowhere and its back to the Cub for a few more components.

A bit of tightening on the back end stuff and some measuring of bolts for the footrest hangers. Need
a couple of new bolts here to tidy things up. A quick polish of some of the units pre fitting and then the
task of fitting the square coil in the round hole game. Things line up reasonably well but I make a
couple of cuts on the left side to make life easier. All back in and connected and ready to test…………
NOTHING !!

Always frustrating when you reassemble something that was working perfectly when you took it apart
so time for some problem solving and question asking. Could the TIG welding have buggered up the
electronic ignition ? Did the system get fried with all the voltage going through it ? Good contacts ?
Good plug and cap ? and perhaps the most simple a good earth ? Everything off again and clean up
all the terminals, a gentle squeeze on the connectors, cut back the HT lead and reseat the KLG rubber
plug cap, and try a different earth point which in this case is the seat post where I had to file the hard
powder coating off. Connect it all up again and success SPARKS !

During the course of all this old friend Forrest Bault drops in as he now lives up at Ridgeway, 120
miles up the road. Several beers later and no further progress, but at least I have sparks and don’t
have to strip out the electronic ignition system so the day finishes on a high and not a low.

With weekend shopping and loading for Sipapu underway just time to fit all the oil tank pipes and
seating assembly. That seems to be it until I’ve been into town for some longer bash plate bolts to
secure the footrest hangers.

Not much left to fit now

Having injured my wrist and with other things stopping any progress on the Dolores 2 Day I’m at it on
the Cub. So far the back end has been finished, bash plate and footrest hangers secured, footrests
back in place, chain on and brake reconnected.

Back end complete

Another clean on the carb which is back on leaving just the tank and exhaust. Exhaust is needing a
mod as with the repositioned front engine plates the front exhaust bracket is now way too long so that
needs cutting down and redrilling.

With the new engine plates the exhaust bracket is too long

Needs shortening and redrilling

With any luck, as section finding is on hold, the Cub may get finished this afternoon. Exhaust bracket
redone and a good fit with even a bit more room up front as the engine is tilted back slightly. Time to
tidy up all the ancillary bits and bobs on the top of the frame such that the slimline tank will fit. Cables
and pipes all seem free. Only area of concern is the crossfeed fuel line which is a bit tight on other
parts. All buttoned up so just polishing to do on Thursday before the reporter arrives to do another
article for the local papers on the upcoming Escalante Days Trial.

Outside for the final photo shoot …….. and then I notice an ERROR !!!  I could not believe my own dull,
dumb, stupid incompetence…….. must have been a “Senior Moment” or maybe the onset of Alts, altz,
homer, heimer whatever…… see if you can spot it ?

With work completed on the Cub and the reporter due to turn up shortly better get the stablemate of
Superglitz shined up in case the camera comes out.

TONY DOWN


CUB IN A BOX


CUB IN A BOX

With plate spinning in full flow and Escalante Days Trial taking shape it looks like I might finally get
round to rebuilding my faithful Cub. She has sat in the workshop since about Thanksgiving. A respite
from weeding at last, and as my non stop endeavours continue I can at last see a time frame for a
good bout of uninterrupted spanner wrenching.

A Cub in waiting

For those who have not been reading the blog the situation was the redesigned 2012 edition suffered
from bash plateitis and gave me some very sudden an unexpected “5’s” as I wandered down trial’s
highways and byways!

Also at some stage some nice kind soul knocked my bike over resulting in the cheap nasty Betor rear
shock rod bending. These were replaced by the identical set off the Enfield so that I could ride last
year’s Escalante Day Trials but had to go back on the Enfield for its upcoming sale. Over the winter a
new set of Rockshocks were ordered and duly arrived in 5 days from the UK.

The dead Betor

New custom Rockshocks from John Bull

Meanwhile Ray cut out the offending lower tube from the frame, fabricated some forward engine plates, rebuilt the footrest adjusters, made a bigger hole for the coil to fit in and reshaped the bashplate.
( see Hell’s Kitchen 13 )

First go at the rebuild resulted in disaster with a self inflicted hole in the crankcase but that has been
subsequently beautifully welded by a local expert after a trail of tears through about a dozen welding
and fabrication shops who all told me it was in the too difficult basket.

Ooops !

So thats where we left it……… now read on:

Saturday 29 June and a thunderstorm rolls in, so no section cleaning this afternoon, the Safari gets a
quick look but too wet for rolling around under the engine so into the workshop and first attempt to fit
the motor after refreshing all the oils.

The transfusion is underway

Close but not acceptable

Suffice to say it “nearly fits”…….. one of the bash plate bolts just touches the crankcase so something
has to be done here. Choices are either use a smaller locking nut or reposition and redrill the plate
and bracket to a point where it is well clear. First I’ll cut down the bolt and nut insert and see how that
is and what clearance I have.

2nd attempt

The engine is refitted and all looks good this time around but now I’m informed guests are coming
for drinks so my plans to complete the front end are slim. Better loosely assemble the back end and
try and line up frame, swinging arm and the rear sub frame and get the SA bolt in to stabilise the
show.

Taking shape

Guests arrive, mission terminated, but with the monsoon season nearly upon us and afternoon rain
I should be able to fit bits and pieces slow time during the coming week, not forgetting more section
cutting for the Escalante 2 Day, lawn mowing, work on the Safari and if I ever get round to it time to
swing a leg over Superglitz for this weekend’s 2 Day over in Sipapu NM.

Another lowish achievement day; shade garden lawn strimmed, radiator on Safari blown out and
hosed several times and another major louvrectomy completed on the upper door. Time to put it back
together and test drive.

Back in the workshop and time to add some more parts starting with the footrest hangers, SA nuts
and the freshly reoiled fork legs. Legs in handlebars on, clutch system all connected and back in situ.
Lower fork leg clamps, fork stops and front brake lever and cable back on. Mudguard and front wheel
would have gone on but…….. more guests arrive for drinkies and today its my old favorite Gin & Tonic.

Plans change again as I needed to get the Safari up and running for the Sipapu event this weekend
and I needed to sort out the rear tire on the bus which leaks ever so slightly. I rang the company that
fitted the tires some 2 years ago and they immediately sent somebody out to sort it out at home! What
a fantastic service and totally unexpected. With that done I went and topped up the LP gas and diesel
so I’m ready to load Thursday night.

Not enough time to go section cleaning so a bit more on el Cubo. The front wheel gets changed to
the old wheel from Superglitz but this needs a slight adjustment to the brake arm as it has new
grooved shoes. It gets fitted and the front end is all aligned and tightened up. The back wheel is
added to give some balance.

Close of play 7/2/13

  My game plan for the day never came to fruition as I had planned more section cutting as the primary
mission with a back up of the Cub if the monsoon dropped by. Brenda goes into town for the weekend
shopping so I’m going nowhere and its back to the Cub for a few more components.

A bit of tightening on the back end stuff and some measuring of bolts for the footrest hangers. Need
a couple of new bolts here to tidy things up. A quick polish of some of the units pre fitting and then the
task of fitting the square coil in the round hole game. Things line up reasonably well but I make a
couple of cuts on the left side to make life easier. All back in and connected and ready to test…………
NOTHING !!

Always frustrating when you reassemble something that was working perfectly when you took it apart
so time for some problem solving and question asking. Could the TIG welding have buggered up the
electronic ignition ? Did the system get fried with all the voltage going through it ? Good contacts ?
Good plug and cap ? and perhaps the most simple a good earth ? Everything off again and clean up
all the terminals, a gentle squeeze on the connectors, cut back the HT lead and reseat the KLG rubber
plug cap, and try a different earth point which in this case is the seat post where I had to file the hard
powder coating off. Connect it all up again and success SPARKS !

During the course of all this old friend Forrest Bault drops in as he now lives up at Ridgeway, 120
miles up the road. Several beers later and no further progress, but at least I have sparks and don’t
have to strip out the electronic ignition system so the day finishes on a high and not a low.

With weekend shopping and loading for Sipapu underway just time to fit all the oil tank pipes and
seating assembly. That seems to be it until I’ve been into town for some longer bash plate bolts to
secure the footrest hangers.

Not much left to fit now

Having injured my wrist and with other things stopping any progress on the Dolores 2 Day I’m at it on
the Cub. So far the back end has been finished, bash plate and footrest hangers secured, footrests
back in place, chain on and brake reconnected.

Back end complete

Another clean on the carb which is back on leaving just the tank and exhaust. Exhaust is needing a
mod as with the repositioned front engine plates the front exhaust bracket is now way too long so that
needs cutting down and redrilling.

With the new engine plates the exhaust bracket is too long

Needs shortening and redrilling

With any luck, as section finding is on hold, the Cub may get finished this afternoon. Exhaust bracket
redone and a good fit with even a bit more room up front as the engine is tilted back slightly. Time to
tidy up all the ancillary bits and bobs on the top of the frame such that the slimline tank will fit. Cables
and pipes all seem free. Only area of concern is the crossfeed fuel line which is a bit tight on other
parts. All buttoned up so just polishing to do on Thursday before the reporter arrives to do another
article for the local papers on the upcoming Escalante Days Trial.

Outside for the final photo shoot …….. and then I notice an ERROR !!!  I could not believe my own dull,
dumb, stupid incompetence…….. must have been a “Senior Moment” or maybe the onset of Alts, altz,
homer, heimer whatever…… see if you can spot it ?

With work completed on the Cub and the reporter due to turn up shortly better get the stablemate of
Superglitz shined up in case the camera comes out.

TONY DOWN

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