Dads Sport Scout

[FLFD7]

Progress….

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[FLFD7]

Went to put the rear frame section on and realized that it would be less of a pain in the azz to get the brake crossover shaft installed off the engine cause the primary case would be in the way. So that’s the way to go…

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While I was at it I put the center stand on cause again it would be easier now then working upside down later.

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[FLFD7]

So might as well do the side stand too…

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Good progress…

[RichO]

Nice work. I can hardly wait to see it on wheels. Great photos too!

[FLFD7]

Moving along….

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[FLFD7]

Well good news bad news. First the good news

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Got the rear frame section on, but not without some fiddling. Which brings me to the bad news

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Here is the issue that required the fiddling around, some interference caused by a special extra tall headed screw Indian used on the side stand mount. The frame mounting screws are all in, so the rear frame is in the proper orientation with the engine and front frame section, yet still this situation. It can’t stay like this because I’d never be able to pull the primary with this screw head in the way. My solution will be to remove the rear frame and ditch the tall headed screw and use a normal screw there. Why did this happen? My only guess has to be with the broken rear frame casting, when it got repaired it might have been just a bit out of position, just enough to cause this interference. I would hope the regular 7/16-20 screw solves this issue. To be continued….

[FLFD7]

Well, using a screw with a normal height hex head made things better

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Because of the shape of the casting over the side stand it will be tough to tighten that screw without removing at least the primary cover, but I don’t envision ever having to do that so I’m good with it. With that I finished bolting up the frame

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A couple little things to do still and I can get it off the bench and onto a rolling stand.

[FLFD7]

While the motor and frame are still on my table I wanted to put the spacer that goes between the motor plate and the inner primary where the hex rod goes thru that holds the floorboard brackets. It’s a tight squeeze and tricky to line up but I got it.

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Glad that was done but once it was I started thinking there is another spacer that goes between the motor plates that the hex rod goes thru, I swore I had it positioned in there but upon further inspection it must have slipped out of place….

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You can just make it out in there, it had slipped down.

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Now it’s going to be a pain in the azz to get it back up in the right spot, I’ll have to loosen everything up so I can slide it up, but since the frame is in I hope I can push it up from the bottom cause I can’t touch it from the top. Make a note if doing a Sport Scout again to put the hex rod and spacers in place before putting the frame sections on.

Hopefully this weekend I can get this off my table onto a rolling stand. That means one of my other projects gotta give up the stand they are on. I have a 101 without to motor in, that’ll be the one I use. I have this 101 racer

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Thats further along. The stands are basically the same, homemade but they do the job and let me move them around my basement out of the way.

[tomfiii]

Be careful tightening hex shaft so it doesn't pull into primary.

[exeric]

I did the same thing, Joe and you have shamed me into taking many things apart to remedy that. I thought long and hard about whistling, and walking away from it, but I'd never get a good night's sleep if I did. I've had, restored, and worked on a lot of antique, and vintage motorcycles over the years and I have to say that the late Sport Scout is the most challenging, and difficult bike I have ever messed with. I'm sure there are tougher bikes, but I'd love to know what they are so I can avoid them

[FLFD7]

I agree with you Eric, this is the 3rd Sport Scout I’ve done and they are just a pain. My late friend Jules used to race Sport Scouts after the war and hated the keystone frame, and as for building them he said you can do two Chiefs in the time it takes to do one Sport Scout. Plus of course parts, especially these days, are hard to come by for the Scouts.

So I decided the best course of action would be to loosen up the motor plates and remove to front frame section. That would give me access to that spacer.

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There it is, slipped down to the bottom.

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I had to tip the engine over so I could push it up from the bottom. You can see it almost in position in the hex rod hole.

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I got it centered right and put the hex rod in place to keep it there, then tightened everything back up. Next time I do a Scout I’m gonna cut a shorter piece of hex and locate both this spacer between the motor plates and the spacer between the primary and the left motor plate so I don’t run into this again. Having to correct hex rod in during this part of the assembly is inconvenient cause it’s so long, but a shorter length should do the trick.

So now I’m about at the point where doing further assembly on a table will be a problem, time to put it on a rolling stand. Years ago I bought a cheap ratchet hoist from Harbor Freight that I use to put bikes on and off the rolling stand. It’s only 500# capacity, but it’s nice and compact and good enough for what I’m using it for. Drag the table under a nice substantial beam and pluck the engine and frame off.

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Then slide the stand under and we good to go.

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So looking good, next up the forks will go on.

[FLFD7]

Hope I don’t fork this up….

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Guess I didn’t….

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A few little things to fiddle with on the dampers and the forks be done.

[FLFD7]

More progress, had to add a little color….

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[tomfiii]

Be careful of spring rubbing paint on neck.

[FLFD7]

Front wheel time…

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Doing it myself, so the motorcycle lift comes in handy

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Tricky to get the brake stay in place, trial and error.

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Eventually it all lines up.

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And there is plenty of clearance between the spring and frame, no rubbing.