Double Trouble

[John H]

This Harley Ironhead XLH clutch has been modified to fit a custom shaft. It was originally a wet clutch but now a dry clutch so required a sealed bearing and Barnett dry plates. To hold the extra horsepower the riveted lugs in the drum had to be welded because the rivets wouldn't hold tight. Last is the custom built lockup pressure plate. This keeps the clutch pack from warping due to the 300# springs used to limit slip.

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[John H]

Scored a full set of finned rocker inspection caps. A bit rough but with some tlc they will do the job.

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As with most projects, it starts with a tool or fixture of some type. Like this one which is threaded inside to match the threads of the caps.

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The diameter will be turned down just enough to remove most of the damages surface.

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[John H]

Using the rotary table to remove the wrench marks. Also resize it to use a standard 1" wrench.
Now they're ready to polish.

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[John H]

Fuel tanks are welded up and ready for final finish and decals. The return fuel hose connects at the top and has a tube attached inside that will carry the fuel to the front of the tank. This reduces the possibility of aerated fuel being sucked back into the system.

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[John H]

All work and no play gets old. So we enjoyed the afternoon just enjoying friends, food and conversation.

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[ATinkerer]

Glad you had a good group.
I've had some sort of bug, (not Covid, I think) and did not wish to share it.

[John H]

I've been sorting ignition parts as the project came with only one magneto. Finally scored one on Ebay which will need rebuilt. Next is making a 3 bolt adapter to fit the pre-unit engine case. Also need to modify a timing gear to fit the mag as well as clear the timing case. I will use the gear that came with the project as a copy to make the other one.

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The 'back' half of the gear must be turned down to clear everything and fit the taper shaft of the mag.

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The next step is to bore the gear and press fit the center part of a auto advance unit in place. This part has the tapered bore that fits the magneto shaft and also the internal left hand thread when used with the sleeve nut loosens the gear on the shaft for the purpose of timing.

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[ATinkerer]

Progress is progress.
Working with custom parts is always a challenge.

[John H]

Thanks Gordon, You have built some radical machines too so I'm sure you know what goes into these projects. I'd like to see some of your work on here. Mark and I are about the only ones using this forum.

[ATinkerer]

Unfortunately, most of my projects at the moment involve tractors and mowing equipment.
Need to get more time with my toys and less fixing trail problems.