Ryan's A.M.C.A. Giveaway bike build!

[Ryan Mackey]

Thanks everyone. When your little most kids ask for pony's or trucks and stuff...well I always asked for a motorcycle and whatda ya know it came true!
It definately has been a white Christmas here in South Dakota...

Matt and I were at it again early this morning. We lowered the headlight to flow a lot better with the rest of the bike. Here it is stock before I cut it.

It would have looked weird stock. I enlarged the second hole on the lower mounting tabs and then cut off the first one that would normally be used to mount it. I also had to bend the top mount down and cut it shorter to fit right.


Here it is all mounted.


After we have our Christmas dinner we are going to continue working on the seat. I am cutting a stock seat pan down similar to a wr seat

[Matthew N. Olse]

Ryan and I had a very productive christmas today. We got his headlight and seat mounts sorted out. Here is a pic of the cardboard templates that we used for the brackets.


Here is the finished bracket. Ryan did a good job of cutting these out.


We put a small reinforcement plate between the two banana shaped mounts to keep the piece rigid. Ryan had to drill and tap a 1/4 24 hole into his seat casting. This bike is starting to turn into a cho***r! Ryan likes it though, and that is what matters. We still need to cut out and weld a piece of strap to the pivot piece for the seat!


Before we shut down the shop, we threw his cases trans and a rear support rod in to try and figure out what we are going to do for pegs and a rear brake pedal. I couldn't find a brake pedal strap for the give away bike, so we are improvising. This is kind of what makes these projects fun. Whatever we do, I am sure it will look really cool.

[bill campbell]

brake strap

Hey Matt and Ryan nice work on the new ride I'm almost sure I have the brake strap but won't be able to dig it out till later this weekend and I'm sure you will have something made by then drop me a line if you need anything I missed donating when you where collecting so now's my chance.
Matt if your thinking of doing this again I have a nice set of 1920 jd case's and some jd parts that I will donate to the cause.
GOOD LUCK ON THE BUILD IT LOOKING GREAT

[36 knuck man]

great work

Matt, great forum, keep up the good work, Larry

[Ryan Mackey]

The snow drifts aren't getting any smaller here...they are almost as tall as me!


We have been working on mounting the seat all day today. The front mount is just about done. Here it is after I made the piece that bolts to the seat and Matt welded it on.


I made small gussets to go on the underside to help with strength and finish off the look we were after. Here they are before they were welded on.


We also got the bolts welded to the seat and decided to weld a flat piece on the bottom so the mount bolts on tight


Now we have to make the mounts for the springs and finish shaping the seat pan.

[Matthew N. Olse]

I spent the day making Ryan's christmas present! Here are all of the pieces that make up his clutch pedal. It is pretty intense stuff, there is a lot going on in this pic.


Here is what the actual pedal started out as. I cast up some 1936 only rear brake pedals six months ago, and have not had time to finish them up. I took one of the raw castings and butchered it up. I cut it in six places and welded it back together to get it in its current set up.


Here is the pivot piece with the grease fitting boss welded and brazed on!


Here it is after a bit of file work


Check out the little spacer that I turned out on the lathe...



We couldn't shut down the shop without tacking the arm to the pivot piece to see what everything looks like. I think that I will have to cut the lever again, and rotate the part that your foot hits forward just a little. We also have to make a stop for it , and do some grinding, but you guys get the idea. I really like how the curve in the lever matches the curve on the front of the primary


Look at that little guy sticking out!


We are having a ton of fun making all sorts of neat little parts for Ryan's bike, Thanks for checking in and enthusiasm. Have a great night.

[1945UL]

this is really awesome the way you guys are posting the progress online. i'm sure theres alot more photo's that arent being posted, and im excited to see what the finished product is going to look like. have fun and enjoy it, this is a truly once in a lifetime experience ryan.

[Matthew N. Olse]

Ryan and I worked on his rear seat mounts today. Here are both of them before being machined. They are in the bar in my left hand


Our original plan was to have a post go through the hole in the frame and be held in place with a spring pin. This plan quickly changed to drilling and tapping a 3/8 16 hole in the bottom which is a much better set up.


Here they are bolted in place


Here is the set up for cutting the flat on the round piece. It is not the sturdiest set up. We only took .o30 passes. It worked well though.


Here is the finished piece after a bit of grinding and filing and sanding.


Ryan cut up the rest of his pan. This pan was in terrible condition before he started. It was theworst seat pan that I have ever seen, I am glad that he cut it up and turned it into something useable.


Here is the finished pan, He did one side first, made a tracing of it and transferrred the line to the other side.

[moon wolf]

Just thought I'd mention that EVERYONE I know is following this thread. It's more the sort you simply follow than reply to. Keep up the great work, guys (I'm jealous, Ryan, and I be a lot of other old guys are, too).

[Ryan Mackey]

I had to tear down the bike today to do some more work on the frame. It was kind of sad to see it back in pieces but she will be back together in no time! We had to silver solder all the joints of the tubes that we replaced. Here is the frame all fluxed and ready.


Carl did the silver soldering, here he is in action! Check out the cool eye protection!


We got the cylinders back from getting honed this morning. Here I am pressure testing the intake to make sure there are no leaks. I sealed the intake valve and the nipple and pressurized it to 10 psi. There were no leaks!


After that I cleaned the cylinders up and taped them for paint. While I was at it I did some other parts for Carl and Matt to get painted too.


Tomorrow we are going to take the frame to get rechecked for straightness. After applying all the heat from silver soldering it is always good to double check.

[Paps]

What did the cylinder bore sizes come out at ? Paps

[Matthew N. Olse]

Paps,
The cylinders cleaned up at .040 over with .004 clearance. They are getting painted as we speak, which is really cool. Hopefully we will have the batch of cylinders back from Mike in a day or two. Our case races from V twin showed up today, so we can heat up Ryan's cases and drop them in. Here are some pics of Ryan taking apart his battery. It had frozen up in the case and had to be broken down to salvage the case and frame.
best,
Matt Olsen



Safety doesn't sleep over at our shop, Ryan made sure that he had protective gloves, ear plugs and face shield so he wouldn't accidentally sniff some battery acid and freeze his brain cells.


Ryan was on his own for this project. I didn't have any good advice or past experience to tell him in regards to breaking old batteries. He just started drilling holes in it and breaking it apart piece by piece.


After an hour or so of work, he had it completely taken apart, here is what a battery looks like in pieces.

[Ryan Mackey]

This morning we took the frame to get rechecked to make sure it is straight. It was really close but is now straight as an arrow!


I decided to cut down the bars tonight. I made the spirals and the grips the same length. First I measured everything out and tapped the threads in the end of the bar longer so that when I cut off the end, I still would have threads to work with. I cut the bars first and filed them flat. After that I cut the spirals to match. Here are the bars before I cut them.


Here they are getting tapped.


And here is the final product!

[Matthew N. Olse]

Today was a good day. We got Ryan's case races from V twin and installed them in his cases. They were a .001 and .0015 press fit when measured at room temperature.
Here is a pic of the cases being heated up before the races were installed. We baked them at 300 degrees for an hour.


Here is the race after we pulled it out of the freezer. We put red loctite on the races just for a little extra insurance.


Here is a pic of it installed



And the other side!



After they cooled off my dad showed Ryan how to line lap the races, here he is getting them hogged out!




Ryan is setting up his cam endplay right now, and hopefully will have his cases painted and sealed up in the next day or two.

[rickgeo]

Hey Guys,
Don't forget to lay down the wrenches & pop the bubbley (choose you're own poison!) tonite!