Shadow Build

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

Re: Shadow Build

Postby John H » Sat Jan 14, 2023 9:22 am

The last pieces to repair on the RFM are the mud guards. They actually welded up ok. Just a bit tricky considering they are old and very thin. George loaned me his mini english wheel which was a life saver. It does a beautiful job of removing those tiny little divots and wrinkles. The front portion of the rear fender was originally for a 500cc Comet which has the drive chain on the left side, so there is a flattened area where the mud guard must clear the chain. With the english wheel I was able to reshape that part and then flattened an area on the right side where the Shadow chain passes.
English Wheel.JPG
English Wheel.JPG (305.47 KiB) Viewed 16596 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 Jan 22, 2023 10:25 pm

The mudguards are as close to perfect as I can get them so will polish them out for the final finish.
Meanwhile I laid out 8 inspection caps/cover for cleaning. They look worse than I recall so here goes another round of cleaning, deburring and polishing, and without damaging the 'Vincent' logo. I made a tool to screw them into so I can re-cut the hex just enough to clean up all the wrench and plier marks. It will be done on the mill using the rotary index tool. It also has a removable stem so I can use it with the hand drill to turn the part when finishing the circumference.
CAPS .jpg
CAPS .jpg (288.02 KiB) Viewed 16553 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 Jan 29, 2023 2:52 pm

After years of using pliers instead of the correct spanner it shows.
Caps1.jpg
Caps1.jpg (220.36 KiB) Viewed 16524 times


With the fixture in the rotary chuck I skim cut just enough to remove most of the wrench marks. The original hex was a bit over 1-5/8" and is now slightly under. Next is more deburring, sanding and buffing..
Caps3.JPG
Caps3.JPG (165.98 KiB) Viewed 16524 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 » Sun Jan 29, 2023 6:11 pm

Much nicer.
Did you make a tool that fits on the slightly modified size? Or does original one still work fine.


BTW, I got my wiper setup going on my Vaporhoner. Still waiting for the intermittent board- but it works very well. I do need to make a little cover for the motor- then a mount for switch and adjustable intermittent operation.
The motor I got was a rebuilt one from a Ford van- so it has park (which is nice).
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 Jan 29, 2023 10:23 pm

I will make a new spanner using some 1/4" thick 2024 aluminum. I'll have to scope out your wiper installation, sounds nice.
[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 » Wed Feb 08, 2023 8:52 am

The inspection caps are finally finished. Quite an exercise in getting the finish and not disturbing the logo. It started with a 2" rotary sanding pad with 400 grit, then 600, 800 and 1000. Then to the a felt wheel on the buffer with white rouge.
Finally into the ultrasonic cleaner to remove all the polishing compound. With final inspection, they were coated with Shine and Seal. On to the next part of the project.
Caps finished.jpg
Caps finished.jpg (275.28 KiB) Viewed 16438 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 Vincent » Fri Feb 10, 2023 8:16 pm

Wow, they look amazing John.
Vincent
 
Posts: 34
Joined: Tue Apr 26, 2022 4:48 pm

Re: Shadow Build

Postby John H » Sat Feb 18, 2023 2:09 pm

Got around to making a spanner for the caps. The original K1 spanner that came in the tool kit was about 1.664" hex. To clean up all the wrench marks they are now 1.625" hex. The new spanner is 7075 t6 aluminum so will be strong enough. I will make an open end version while I'm at it.
K1 spanner.jpg
K1 spanner.jpg (200.34 KiB) Viewed 16354 times
K1spanner2.JPG
K1spanner2.JPG (193.66 KiB) Viewed 16354 times
Attachments
K1 spanner1.jpg
K1 spanner1.jpg (180.84 KiB) Viewed 16354 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 » Sun Feb 19, 2023 9:50 am

Looks great. I was wondering how you were going to make the ‘square’ corners. But doing them relieved instead works better and much easer to do also.
I will keep that in mind.

Have you ever cut a woodruff ‘slot’ inside a flywheel taper?
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 Feb 19, 2023 2:06 pm

I made a couple of mistakes but the dimensions are correct so will live with it. This old rotary table has seen better days and was difficult hitting the 60º marks.
[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 10 guests

cron