101 Scout... going to take a while

[pisten-bully]

Next up was the RH handlebar, a messy sausage looking thing so I decided to replace the right side only



Cut off the old bar and had a friend mill out the casting so that new tubing could be installed, and since he was so helpful he cut the slot for the cable puller. We decided to simply match the rise of the new bar to the LH side, even though the 101 R&O manual tells of a different rise!

[pisten-bully]

I went for completion on one item to show myself some progress! The saddle was pretty much an incomplete skeleton so I worked on that first (last year...)

The pan was in trouble, some cracks and blown out holes:



So I did some welding up of the holes and cracks, and fabricated a missing threaded insert for an optional Mesinger back rest (which I don't have)



I also needed a few parts (there's a bunch of parts in one of these seats!), but the few missing parts were available through Walker



...and sent the seat off to Michael Paquette of Worsham Castle... I am quite pleased with the results, thanks Michael!

[Tom Lovejoy]

Looking forward to your up dates

[exeric]

Very well said, Mike. Like you said, when a person humbly says they feel overwhelmed by a project, you know they are going to do everything they can to find the information they need, and do the job correctly. Of course it's also beneficial to see how an expert does something as well Pictures, and text are the key, however.

[ihrescue]

It's very difficult to stay on top of a build thread. Taking pictures at critical junctures often interferes with the enthusiasm of the project. . . But, it's worth it, and I think most everyone will agree that a build thread is their most favorite feature on this forum.

You're spot on Eric, member builds is my my favorite to see how others approach problems as well as to to have a sneak peak at their work area. I follow garage builds Garage Journal, wood machinist chest restorations, even off the the grid homestead builds, anything with a serial build is of interest. I know on this thread the it started out with "This probably won't be very good, but here it goes." That couldn't be further from the truth. Plan it, build it, document it. It is of huge value when preserving the heritage of old stuff. Thanks

Mike Love

[exeric]

It's very difficult to stay on top of a build thread. Taking pictures at critical junctures often interferes with the enthusiasm of the project. . . But, it's worth it, and I think most everyone will agree that a build thread is their most favorite feature on this forum.

[Green Indian]

I second that, keep up the good work Harry, that 101 is going to be great!
Damon

[pisten-bully]

Keep up the good work. 101's are special!

Thanks Doug, and now I feel like I shouldn't have started this thread because it's very difficult to keep one of these threads current! When I have the spare time I will work on the 101...OR I'll ride my Chief and completely neglect updating the build report on the internet! BTW, I continue to use your build story and pictures as reference, extremely helpful, thank-you! So I will put some time into updates....after Labor Day! I've made progress!

[djones]

Good job splitting the tank. I did the tank on my 101, and it is a job, but worth the effort. Getting it clean is the key, and a lot harder than it seems. I also made the mounting bungs much bigger diameter than the originals, which gave more bearing surface inside the tank.

Keep up the good work. 101's are special!

[pisten-bully]

Well, not much to to report as it’s now the summer ride season and I concentrated on getting my Chief ready, and then riding it! But I have run into a question about the holes in the casting for the kicker return stop. The forward hole had a broken off bolt in it.



I tried a couple of methods for removal but then resorted to drilling and re-tapping. When I drilled the front hole I could go deep into the casting, but with the rear hole it appears that there is either another broken bolt in there, or that rear hole requires a short bolt as the frame tube is brazed far enough into the casting to keep the hole shallow.

So I wonder if anyone can tell me if the rear hole for the kicker stop is normally shallow like this? Thanks!

[pisten-bully]

Not much to report (things got very busy with work... the paying kind) but I did acquire a new wrench. I like tools, I've got three sets of them (warehouse, home, shed) but I didn't have a suitable wrench for removing the head adjusting cone in order to remove the forks. I used a strap wrench until the strap started to shred, so then I bought this beauty, an adjustable hook spanner :



Worked great and now I have another tool! Got it from ZORO.com. Their item# GO494155, $27.84 (it's marked PROTO, mfg #JC472) Should work on my bicycle, too!

[Tom Lovejoy]

very cool, watching with interest

[pisten-bully]

Nothing special here, but this is how I split the tanks. Using a soldering iron I worked my way around the tank on the seam and inserted popsicle sticks to keep the halves apart (the job would've been much more pleasant had each stick originally held a treat). The corners were tight and I changed to utility knife blades.

[TH47Indy]

I've learned a lot from from your other build thread so I look forward to following you on this build.

[painterdale]

Works for me, Harry!
Dale