Shadow Build

If in doubt, or it doesn't seem to fit elsewhere - put it here.

Re: Shadow Build

Postby John H » Wed Nov 09, 2022 7:28 pm

Today was not a good day :? The brake drum assembly rolled off the bench and broke a small chunk out of one of the fins.
If that wasn't enough, in the process of taking it all apart I broke a piece out of the hub trying to get one of the bolts out.
I got the drum welded up and while it was cooling I located another hub and cleaned it up in the lathe. While I have this disassembled I machined up a couple of pieces so I can bend the spoke flange a couple more degrees so the spokes can be added or removed anytime without loosening the bolts.
Spoke flange mod..JPG
Spoke flange mod..JPG (222.03 KiB) Viewed 14147 times
[i][color=#4040BF]John[/color][/i]
John H
 
Posts: 1065
Images: 8
Joined: Wed Jun 13, 2012 10:19 am
Location: Northwest

Re: Shadow Build

Postby John H » Fri Nov 11, 2022 9:06 pm

Today was a make lemonade out of bad lemons day. I machined down the destroyed front hub so I can bolt the brake drums on and true them up.
IMG_6392.JPG
IMG_6392.JPG (285.27 KiB) Viewed 14138 times


The brake drum that was damaged in the fall from the bench was more than just chipped. It was actually bent .020" out of round. So another 'special tool' was made to jack it round again. I got it within .005" and finished it off with a light skin cut.
IMG_6394.JPG
IMG_6394.JPG (257.95 KiB) Viewed 14138 times


Note the rubber bands around the drum. This helps stop the harmonic chatter that happens when turning a disk or drum. Another trick is holding a chunk of lead on the part while making the cut.
IMG_6396.JPG
IMG_6396.JPG (218.56 KiB) Viewed 14138 times
[i][color=#4040BF]John[/color][/i]
John H
 
Posts: 1065
Images: 8
Joined: Wed Jun 13, 2012 10:19 am
Location: Northwest

Re: Shadow Build

Postby John H » Tue Nov 15, 2022 11:27 pm

The wheel hubs are finished. The Borrani alloy rims that have been in storage for at least 25 year are slightly tarnished but will clean up with a bit of Blue Magic. The wheel/tire combination 19/20 was standard on the 53 Shadow so I will stay with that. If it was going to be ridden a lot I would change to a 18/19 combination for better tire options. Still waiting for spokes.
Attachments
Wheel brake truing.jpg
Wheel brake truing.jpg (220.47 KiB) Viewed 14096 times
IMG_6405.jpg
IMG_6405.jpg (292.47 KiB) Viewed 14096 times
[i][color=#4040BF]John[/color][/i]
John H
 
Posts: 1065
Images: 8
Joined: Wed Jun 13, 2012 10:19 am
Location: Northwest

Re: Shadow Build

Postby Lotus54 » Wed Nov 16, 2022 11:59 am

I imagine a fairly limited choice of 20” tyres.

Looking good!
1976 OSSA Super Pioneer- 78 Benelli 750 sei,72 250 2C Benelli, 68 Benelli Dynamo trail, 76 OSSA GPII Phantom, Beta XTrainer 300, Lotus Elan S3
User avatar
Lotus54
 
Posts: 587
Images: 0
Joined: Tue Jun 12, 2012 9:13 pm

Re: Shadow Build

Postby John H » Sun Nov 20, 2022 12:21 am

20" front tires are a bit odd but but still available from Avon. Probably not a good choice for long distance touring. Most rear wheels are 18" but 19" was common on early bikes.
I dug out some sprockets to see what would be a good medium range setup. I found a good combination (21/46) that was actually made for 520 chain instead of 530. The 520 was used on the Lightnings and with modern chains I think it's a good choice.
The rear wheel was designed to carry two different size sprockets, one for average riding and one for a full load or sidecar rig. I will mount just one sprocket and attach the 'water excluder' to the opposite side which is suppose to help in keeping water out of the brake drum.
IMG_6422.JPG
IMG_6422.JPG (206.71 KiB) Viewed 14067 times
IMG_5619.JPG
IMG_5619.JPG (248.85 KiB) Viewed 14067 times
[i][color=#4040BF]John[/color][/i]
John H
 
Posts: 1065
Images: 8
Joined: Wed Jun 13, 2012 10:19 am
Location: Northwest

Re: Shadow Build

Postby John H » Mon Nov 28, 2022 10:46 am

It's officially the Christmas Season so let the shopping begin. The Shadow will have to wait.
My grandsons 10 and 11 are tool nerds and in the past I have restored a 1930s drill press and a bandsaw for their Christmas present. This year it will be a 1930s Craftsman wood lathe. Original catalog price $4.85. Some stripped threads, main shaft and bushings need repaired. Also the tail stock shaft and knob need attention. Motor seems ok but will need disassembled, cleaned and tested. Hope they enjoy it as much as I have restoring it.
img8.gif
img8.gif (136.6 KiB) Viewed 14012 times
IMG_6456.JPG
IMG_6456.JPG (424.32 KiB) Viewed 14012 times
IMG_6463.JPG
IMG_6463.JPG (234.2 KiB) Viewed 14012 times
Attachments
IMG_6461.JPG
IMG_6461.JPG (202.02 KiB) Viewed 14012 times
img23.gif
img23.gif (82.17 KiB) Viewed 14012 times
[i][color=#4040BF]John[/color][/i]
John H
 
Posts: 1065
Images: 8
Joined: Wed Jun 13, 2012 10:19 am
Location: Northwest

Re: Shadow Build

Postby Lotus54 » Mon Nov 28, 2022 12:57 pm

That is really cool.
Want an old dental handtool setup for the chair to restore? Ha (not sure what I’m going to do with it)
1976 OSSA Super Pioneer- 78 Benelli 750 sei,72 250 2C Benelli, 68 Benelli Dynamo trail, 76 OSSA GPII Phantom, Beta XTrainer 300, Lotus Elan S3
User avatar
Lotus54
 
Posts: 587
Images: 0
Joined: Tue Jun 12, 2012 9:13 pm

Re: Shadow Build

Postby John H » Fri Dec 02, 2022 12:17 am

Ha, I can only imagine a set of dental tools in a little boys hands.
Had to do a motor rebuild today for the wood lathe. The contact surfaces were pretty bad so took a skim cut. Found some 5/16" diameter carbon contacts so will see if it fires up next.
IMG_6477.JPG
IMG_6477.JPG (235.81 KiB) Viewed 13974 times
IMG_6481.JPG
IMG_6481.JPG (233.43 KiB) Viewed 13974 times
[i][color=#4040BF]John[/color][/i]
John H
 
Posts: 1065
Images: 8
Joined: Wed Jun 13, 2012 10:19 am
Location: Northwest

Re: Shadow Build

Postby John H » Sun Dec 04, 2022 4:44 pm

All that work on the cute little motor only to find that the rotation is wrong, that's if it is installed under the lathe. Otherwise it would be out past the end. It will get used for another project and a bi-directional motor will take it's place.
IMG_6500.JPG
IMG_6500.JPG (217.61 KiB) Viewed 13949 times
[i][color=#4040BF]John[/color][/i]
John H
 
Posts: 1065
Images: 8
Joined: Wed Jun 13, 2012 10:19 am
Location: Northwest

Re: Shadow Build

Postby John H » Sun Dec 04, 2022 6:11 pm

The wood lathe is finished so back to work :?: The stainless steel spokes finally arrived!! I ordered them with a 'mill' finish as I was contemplating a bead blast finish to match cad plating. After looking at the beautiful Borranis again I decided to polish them.
IMG_6405.jpg
IMG_6405.jpg (292.47 KiB) Viewed 13948 times

I use to have a centerless polishing lathe made for polishing very small diameter round bars but I have also done it this way and it works fine it just takes a lot of precaution. The small wheel is a Scotchbrite wheel that deburrs as well as smooths the surface to a satin finish. The large wheel is a fine stitched linen buffing wheel.There's a little more to the process than you see in the photos.
IMG_6502.JPG
IMG_6502.JPG (196.71 KiB) Viewed 13948 times
IMG_6503.JPG
IMG_6503.JPG (167.09 KiB) Viewed 13948 times


One done, one to go.
IMG_6513.JPG
IMG_6513.JPG (303.76 KiB) Viewed 13948 times
[i][color=#4040BF]John[/color][/i]
John H
 
Posts: 1065
Images: 8
Joined: Wed Jun 13, 2012 10:19 am
Location: Northwest

PreviousNext

Return to General Discussion

Who is online

Users browsing this forum: No registered users and 6 guests

cron