Dads Sport Scout

[pisten-bully]

...for what it's worth, '46 Chief has piano hinges:

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[FLFD7]

Hey Pisten,

yeah, I got one of those boxes too. It looks like it was repaired at some point since the hinge is spot welded to the body but riveted to the door. That’s why I decided to rivet mine

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Something I noticed, I don’t know if it’s a later year thing or a Scout vs Chief thing but the speedo cable notch is lower in the 3 hinge box and is more formed then the higher cutout on the piano hinge box.

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Ok, I just answered my own question, see above from Greers website, I guess the 3 hinge box with the lower notch only fits 41 and 42 Sport Scouts.

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The Chiefs and Fours had the notch up higher.

[FLFD7]

Did some more work on the toolbox since I got the gasket I needed from Greer. First off, for me, I had to trim the gasket.

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It is way too tall for this toolbox, to the point that I couldn’t close the cover enough so that the lock would catch. I gave it a trim with my EMT shears and it was better, to fine tune the size I pinched the gasket in a vice and took a coarse file to it and that worked. The final trimming would wait till after the hinge was on.

I bought a piano hinge from McMaster Carr that had the same dimensions as the small hinges that were on there. I lined up the knuckle of the (pre drilled) hinge with the edge of the cover, marked it and pop riveted it on.

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Then to ensure the cover closed with the gasket in place I used a punch to flatten the inside of the rivet. Once the door was done I put it on the box, made sure it latched nice, and marked the box itself I tried drilling the box but there was a bit of “give” to it so I made a little brace in the inside so I can drill it properly. After that it went fine.

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I’ll fill in the holes in the rivets with a little JB weld and then give it a shot of paint to kinda blend in the hinge, got my fingers crossed it looks decent.

[FLFD7]

I painted the new hinge inside and out then went over the outside with some fine sandpaper and 3M pad to kinda weather it a bit.

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Then a little compound

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And finally a coat of some liquid wax

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I think it gives it enough fake patina that’ll blend in with the real patina on the rear of the sheet metal.

[FLFD7]

That should be “rest of the sheet metal “

Anyway, since I’m still waiting on my cylinders I’ll work on the wheels. Years ago at Wauseon I picked up a set of 16” Scout wheels with tires mounted for a decent price. I’ll use these for my dads bike.

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The rear tire on my dads bike has a neat original Goodyear Grasshopper, but someone welded the drive sprocket to the hub and there are a few messed up teeth on the sprocket, so I’ll swap the guts and backing plate and we should be good. I’m toying with the idea of reusing the Grasshopper on the new wheel, don’t know yet.

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The front wheel on the bike was an 18”, but the tire has a hole in it you can put your fist thru. Since I’m going to use the new 16” wheel on the back I’ll match it in the front.

[FLFD7]

A slight detour before I tackle the wheels wanted to touch the rear fender up from where I had the welding repair done. I cleaned and painted the repair areas on the inside in a similar blue, didn’t have to be perfect cause inside won’t be seen. Cleaned and compounded to outside, there had been some touch ups in other spots on the red panels so I knew the color doesn’t have to be spot on.

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When I was finished I realized I picked the wrong pain can, a different red then I had used on the tool box, but actually was quite surprised with the results, color match not too shabby, no worse then the previous touch ups that had been done. Let it dry a couple of days then gave it a coat of liquid wax and I’m happy with it, a lot of the repaired area will be hidden by the frame and shock anyway.

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Shiny…

[FLFD7]

Well, still waiting for my cylinders…..

ok, there’s other stuff to do, I’ll finish up with the rear fender. I put the fender tip on and then the taillight

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ran the armored wire thru a new grommet should be good to go. Looks nice anyway….

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So I had turned the lights down for the last picture and as I was moving my test leads back and forth from the taillight to the brake light I noticed some sparking from the armored cable, and the cable was hot to the touch….fudge, must have a short….well it is 80 year old wire….

[FLFD7]

I thought I had some armored wire but couldn’t find it so I’ll use regular cloth covered wire and some wire loom cover, better then nothing. Got to reuse the little Bakelite pieces from the end, I had part of another taillight wire so use that and save the original for reference.

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I cut some wire extra long and resoldered the end on.

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looking good, I put the end in the socket with the bulb and lit it up, should be fine.

[pisten-bully]

...too late now, but there is a source for that armored cable....I just don't remember who the vendor is

[FLFD7]

I started going through another box of wire that I have and what do I find in the bottom?

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Oh crap, I thought I had some. Well, I’ll just make it again….

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Now I feel a little better about it that it’s the armored wire. I put a couple bullet connectors on the other end like the original.

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That ought to do it.

[FLFD7]

Since I was messing around with wiring up lights I figured I’d do the front fender light. Made up some wires (I decided to run a ground cause you won’t notice the extra wire really behind the fork cover plate). The guide strips inside the fender were mashed down at some point but I pried them up enough to get the wires thru and some cable loom to help protect them.

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I got a frosted LED bulb, it’s only like 5 watts. But it is bright. Maybe too bright.

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Still waiting for the cylinders….sigh….so on to the wheels.

[FLFD7]

Time to get the hands dirty, gonna get the guts out of the 18” front wheel to swap into the 16” wheel I’m gonna use.

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There is a retaining ring under that grime somewhere…there it is. Just a lot of dirt and grease buildup. Getting the nuts off a bit of an adventure, all I can say is a little bear and penetrating oil is your friend.

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Thats it for the taking apart part, now a bit of cleaning and reassembly.

[FLFD7]

Looks like everything there

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The brake linings look shot, I’ll have to address that.

[FLFD7]

Still making progress. On a positive note the machinist actually answered my phone call and told me a couple weeks more for the cylinders to be done.

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Yeah, the linings are shot. Fortunately I have replacements.

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Got everything cleaned up, gonna use new bearings cause why not.

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Backing plate done. Only issue I see before everything back together is the wheel felts. I ordered some new ones from Greer but they look too thin to me, they don’t sit above the edge of the spacer cup. (The felts in the picture are original from the wheel ). Once I figure that out the wheels done.

[FLFD7]

Ok, moving on with the front wheel hub, got everything cleaned up, ready to go back together.

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So everything went back smoothly.

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And I decided to go with Greers felts. On the non brake side of the hub I tried another felt I had that was thicker, I kept rubbing it on some coarse sandpaper to peel away some of the felt but didn’t like how it turned out so I used new.