83 CR500, here begineth the lesson

[Wildebeest90210]

Put the forks together today. I got them on Ebay for £26 powder coated and fitted with new fork seals.
There was some damage to one bush which I took out with a small die grinder. That fork is a little sticky though so I will strip it again.
Anyone know what tolerance the bushes are and how to measure them, ID or end play?
And also they look tricky to get out.

 

[Wildebeest90210]

Seems like a good project i fancy road registering my XC 430 done this before with a Kwak 250 how did you go on getting a sertificate of newness i tryed but got nowhere ?? could you let me know how you did it if poss

Husky Sport near Winchester did the cert. It cost £60 though which I wasn't expecting. I talked it over with various people before I paid about the value of age related over Q plate and reckoned it was worth it in the long run so bit the bullet. Can't remember the name of the bloke but the number is 01962 771 122.
I could'nt find anyone else to do it, not even Husky UK. They only do back to Cagiva stuff I think.

 

[Wildebeest90210]

Fork problems. Stripped the fork that binds and found damage on the bottom of the stanchion. Looks like something was embedded in the fork leg. Polished out the damage and it looks like it will sit under the seal, Just. Honed the inside of the leg as it had a couple of dings as well.
I noticed the fit is very tight. Bizarrely enough the fork leg ID is 40.13mm while the bush as new is 40.19/40.20. The leg is a better fit than the bush !!!??? This was the same in both sets of legs I have.
Run out on stanchions is 0.6mm and 0.3mm which I reckon is ok.

 

[Wildebeest90210]

Shiny and new, freshly made today.

 

[Wildebeest90210]

Dennis came through this week. Still waiting for crank, cases stripped and ready to pick up Tuesday.

 

[Wildebeest90210]

Made in Sweden.

 

[Wildebeest90210]

A mock up, making new spring spacers and collets off for powder coating.

 

[Wildebeest90210]

Wow, I'm putting stuff back together at last. And got cases back vapour blasted.

 

[Freaky]

Cases look like new, were the shocks and yolks originally blue?

 

[Wildebeest90210]

Cases look like new, were the shocks and yolks originally blue?

Theres a thread called '430 case composition' on the general vintage forum about the cases. I just left them with someone I trusted and they ended up vapour blasting them. On Ally it looks better than new and supposedly peens the suface so it keeps the finish looking good for some time. I have them lined up to do my head and barrel when they are ready.
The shocks yokes and also the fork legs were blue (see very first pic on thread). Not sure what the colour is, I would call it 'early 80's spangly blue'. I'm sure a mate had a vauxhall viva in the same colour once, I suspect Husky never used it though.

 

[hvaloz2]

Dennis came through this week. Still waiting for crank, cases stripped and ready to pick up Tuesday.
View attachment 13835

here beginith the bling

 

[Wildebeest90210]

Today was all white.

 

[Wildebeest90210]

Things coming along. Best news is the bank have approved my new credit card so I can get down to HVA factory and have a massive shopping spree. Good thing the wife will never ever read this.
Heres the rebuilt shocks and ref BMX comment earlier, sparkly dice caps. Pure 1983!

 

[Wildebeest90210]

I know all these posts are not really that riveting but I am finding it helps me do something every day. Chip chip chip..
Spotted the front spindle clamps, before and after;



Rear wheel spindle and S/A spindle



Seems like every single part of this bike needs attention. Scaring sheep and scattering ramblers seems a long way away.

 

[GaryM]

We like them all - please keep posting/sending them. What product are you going to paint your Vapor Blasted cases with ??

Thanks
Gary in Austin TX

 

[Wildebeest90210]

I'm going to try a two part polyurothane acrylic (I think). Got to get the bearings in first though. Great posts on this forum helping me though, timing side first then pull up the drive side. What could possibly go wrong ?!! Going to use the same oven I just cooked this masterpiece of a pie in.....

 

[Wildebeest90210]

Latest pic, kickstart gear been eating in to the casing all contributing to the grinding paste gear oil. I will make up a phosphor bronze bush for this unless anyone knows of a better fix?
Will split cases this week. Mains def shot, gears all select and drive by hand so fingers crossed.
Might dig out a pick of the Stormer Mike, a 370 built from a box of bits when I was 14. My Dad couldn't believe it when it ran. I couldn't believe it when it spun 180 on the very first corner, I stayed on, if I hadn't I'd probably be playing golf instead now.

View attachment 13224

Didn't clock this up as the outer casting may not be concentric and the inner has worn towards the top of the case. Just dropped a 3mm drill on to the centre of the original drilling by eye. I will open up the oilway at the back to get a bit of extra lube on the bush(still to be made). I guess there is a bearing here originally?

 

[White Husky]

There's some real skill and, dare I say it, Love going into this build. I take my hat off to you. It looks awesome.

Kind regards
Lucien

 

[Wildebeest90210]

Just purchased. Off with the BMX bar guides and a classic lightweight mesh 80's MX plate.

http://www.ebay.co.uk/itm/180806032021?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1497.l2649

 

[Wildebeest90210]

Just got my tank back from Dennis the paint man. Lovely finish but something just doesn't look quite right......