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Henderson headache

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  • Henderson headache

    I just want to snivel a bit about this 1917 Henderson I am trying to finish for the Eustis meet. From day one it has been a slave driving, whip weilding, taskmaster. I started on the engine first and quickly found out it had a bent crankshaft. Two trips to a crankshaft specialist got it straight. I put the bottom end together and discovered the countshaft saddles were out of wack, (not perpendicular) to the crankshaft. I know a good welder who cussed a blue streak about that case but he did a good job and built up the right areas. I tied up a Bridgeport mill for a whole day, (and got paid for it, but I don't work there anymore.) I used every angle plate and hold down clamp in the place and must have worn out a dial indicator getting it aligned. One light cut with a boring bar and it was done. Everything lined up and spun smooth as silk. Of coarse I had to make all new bearings, spring pockets for the clutch, tappet guides, tappets, valve guides, thrust washers, spacers, and thrust bearings. Also repace every ball bearing, bushing, spring, and fastener.

    I am reluctant to mention the starter nightmare. I have a 1919 Hen as well, and both bikes have the most poorly designed starter I have ever seen on a motorcycle. It's small and fragile and you'll never find good NOS starter parts. I believe every dealership was cleaned out of starter parts many years ago. If you have a '17 - '19 Hen, treat your starter like newborn baby. After numerous experiments I was able to make a starter with the right tooth angle and hardness. ...... And I still don't trust it.

    The frame looked good at first but after putting the thing together I discovered it was very badly bent. My theory is, it was hit by something fast and heavy in the right rear. The damage went from the rear to the front and even broke the left leg of the main fork. All of this had been half/arsed fixed by some nincompoop in the past. I spent countless hours cutting, welding and straightening that old tubing and eventually got it to measure out square.

    Next came the body work. Whatever traumatic event wrecked the frame also warped the sheet metal. I've had a lot of experience with warped fenders and I can get them straight again but I hate sheet metal work more than anything. Of coarse that involved a lot of cutting, brazing, and grinding. Just thinking about it makes my skin crawl, but the fenders came out beautifully.

    Before getting everything ready for paint, I put it together for a dress rehearsal. This is where you find out what doesn't fit and why all of the stuff that should theoretically work, doesn't work. After tons of adjustments and redesigns the dog-gone thing started up and ran.

    I tore it down and started with the paint. Everything was going great, perfect weather, and countless hours of surface preparation rewarded me with a flawless dark blue paint job. Next came the striping and the decal application. That's the big reward, to see it striped and with that beautiful winged wheel decal on the tank. . . . I was in heaven. A few coats of clear over everything would protect it and I'd be done. I was doing the tank in clear when my hand bumped into the decal area and pulled a big chunk of the decal off. I think I might have passed out because I can't account for a couple of hours that day.

    Needless to say, I reworked the tank and thanks to Bob McClean, new decals were expedited and applied.

    Yesterday, (Wednesday) I got the bike back together and finalized the assembly. I made sure everything was tight and locktighted, air in the tires, oil in the motor, gas in the tank, and the right firing order. The original gas cock is leaking like a kitchen faucett. I worked like an idiot to get the genuine petcock to work and now it's leaking. Off to the hardware store for O-rings and some late night machine work and now it's only leaking a little bit.

    After a good nights sleep I felt confident it would start right up this morning. After 10 kicks it was obvious it wasn't going to start. My investigation revealed a stone dead magneto. That mag worked perfectly 3 weeks ago. The thing that really kills me is, that was the one component that was seemingly perfect. It was rebuilt by a well known California magneto guy (who I won't name) and it was the one thing that I didn't think I would have any problem with. I have an appointment with Ed Strain in St. Pete tomorrow morning and he's the guy I wish had rebuilt this magneto.

    I joined the AMCA back in 1975 and I've been going to the Florida meet every year since then. Here we are on the eve of the Florida meet and I'm sitting on my hands with a stomach in knots waiting to find out if it's even going to be worth going this year. Well, I'm going to stay with this to the bitter end. I'll let you know what happens tomarrow.

  • #2
    This is my first picture post so I hope you get to see America's most evil motorcycle.
    Attached Files

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    • #3
      Exeric,
      You sure have a beautiful and unusual motorcycle and your almost done. It sounds like you've solved some very sophisticated problems and you will have no problem solving those that surface here at the end. There's nothing more frustrating than trying to meet a deadline. Step back and take a deep breath and if you can't meet the deadline just forget it. You're almost there and the few problems you have left can be more easily worked out in the calm after, rather than during the storm. You have a treasure to enjoy for many years to come; it's only the beginning of the fun.

      Howard

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      • #4
        Pretty sweet Henderson Exeric!!!! Sounds like a resto that you won't soon forget. You know the old saying " If it were easy everyone would be doing it!!!" It'll be awesome when it fires up!!!!

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        • #5
          Shes' a beauty!!! Hang in there. I also have felt your pain. As I'm certain lots of us have. YA!!! It's good to sound off sometimes. Hee-hee... Let us know diagnosis of mag - I'm certain it's something minor.

          You have discover why some projects keep getting passed. Your a good man for putting in the hours and bring that Hend back from the grave. A toast to you sir! What did you use for babit bearing?

          Ignore your personal dead line and just take the bike as is.

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          • #6
            I went tro see Ed Strain this morning. He took the mag apart and discovered it was a cosmetic job. The coil and condenser were the original units and were re-potted in epoxy to make it work a little longer, which means just to sell it. Ed is a man of high ethics and assured me that is not how you rebuild a magneto. I am not going to mention the name of the man who rebuilt it but I would advise others to seek out a reputable magneto man to do your mag.

            I just put the E-41 Berling mag from my 1919 Hen on the '17 and the bike just started. It runs nice and smooth but I have a float bowl problem and gas is pouring out of the intake elbow. On a Henderson of this vintage that problem could be disaterous because the carb gets warm air from the header. . . . . However, that would end the problems.

            I apologize for venting all of my problems on the forum. Writing about all of this has been good therapy but that doesn't mean anyone wants to hear it. Anyways, it looks like it might work out now, so thanks for putting up with this.

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            • #7
              It's good to hear these things. This is the place to vent. It may help others.

              OH YA MON! Cap & Coil need to be replaced. Yellow jacketed caps were a little more but better quality. I can't remember capacitance rating - but they worked well on the bench (scope) and over time in the field. A modern winding is much better quality as the wire is coated. Orig it was shelacked after each pass or something - would break down, short= weaker spark.

              The epoxy is a little vibration/water seal insurance. That's a good thing. Ya kinda surprising cap and coil not replaced. Maybe something was grounding out? Which can happen. Oh well - it's done. Yes, you have to tell these guys "I'm going to ride the bike".

              Great to hear she runs. Float needle not closing eh! Sounds familiar.... all the nitty-gritty details that make it work. Got any oil leaks? Such fun.

              Watch out for the engine lumbering along after 60-80 miles from heat. On new engine she may start to sieze. They get really tight from heat on break in apparently. That's just what I saw and heard. May be incorrect.

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              • #8
                1917 Henderson

                Exeric, you have no idea how people like you make mere mortals like me feel.
                Your engineering skills and restoration experience is inspiring to say the least.
                From a back yard hacker, congratulations on a superb machine.
                My 1922 Powerplus will never have the fit and finish like your bike without me paying my next years wage to someone else!
                Fantastic restoration report mate.

                Best wishes from Australia.

                Ken.

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                • #9
                  Exeric, you know all us old bike freaks like to hear about how the job went down.....troubles and all!! I agree with Baytown, your an inspiration to us backyard fellas (with not near enough machine equipment!!!!) It's also good to hear about the troubles you had as it may help others that tackle a similar project. But I guess Admin-dude said all that already. Thanks again for sharing with us. You've put together a stellar machine.......I just wish you could post audio so that we could all hear it run!!!

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                  • #10
                    the problem with the clear coat reminds me of my last restoration. I was applying a light clear coat over a perfect paint job outside in my back yard and was hanging my tanks from my kids old swing set. The wire that was holding the left side tank broke right after I finished spraying and fell into my freshly cut grass. I was pulling grass blades out of the clear coat for hours, sobbing all the while. Of course I had to redo that entire tank after I got over the whole thing.

                    Jim

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                    • #11
                      Eustis Henderson

                      I saw your bike, it sure is a beauty! WOW!

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                      • #12
                        Thanks for all the great comments. Things worked out pretty well and Eustis was a good meet this year. The only problem was I caught a cold. Now that I'm back home and taking it easy, my mind won't rest and would you believe I wheeled my 1916 Excelsior into the shop and am seriously thinking of tearing it down and going all through this again. . . . . . . Jeeze, I must be nuts.

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                        • #13
                          This is the '16 X. I wish I could send bigger pictures but I don't know how to do that.
                          Attached Files

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                          • #14
                            Holy Cow Eric!!!! Your garage is just full of goodies isn't it? I've got a real weakness for the ol' X machines.........Does it need much for work? I think it looks pretty good the way it is....... I hope you keep us informed on your progress........

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                            • #15
                              Wow Eric- the 16X is really neat. I don't think your nuts, I think your retired and is a lookin fur somethin tuh do.

                              The photo is getting pretty close to max size. 600x600 pixels under 70K. Looks good.

                              Is that the 1916 correct color? I've only seen a few X's in my life. I'd love to see that bike run. Again.....wow......

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