Wednesday 27th July - Shed night

Picked up the leaf spring from the suspension shop.

It looks ok & they only charged me $30.

Not 100% correct but it should work.

I bought 3 wheels up to shed....

one off the '47 chief (16" wheel),

a BSA front wheel with brake & a 19" british wheel.

The BSA front brake was to big so another error in my purchasing .... dammit

The 19" brit wheel was hopelessly out of round .... but we will use the hub & lace it to another 19" rim which Wayne gave to me.

I removed the spokes from the 16" wheel & got the bearings out of the hub. I will need to seal the middle before blasting.

Wayne & Andrew made a start on my front barrel. The exhaust port was broken. We tried to rebuild the metal with Chris's electric welder but the bronzing from previous fixes made the job impossible. We will now get it cut off & a piece threaded in.

Chris gave me an old seat pan from a 20's bike, complete with springs. The nuts had nearly rusted thru to the bolts.

I had to get the grinder out to cut the bolts. Luckily they all came away without damaging the pieces.

There are a lot of specialist bolts which I will need to get made in order to rebuild the seat.

These seats only have the rear of the pan with most of the saddle stretched leather. There is a bolt at the front which I guess is uses to straighten the leather as it stretches

Also had to grind off the spokes from the 19" rim.

The guy at Ironwigwam had forgotten to post the pistons so we are still waiting for these b4 we can start resizing the flywheels .

Incoming packages

A lot of the parts I ordered a few weeks ago have been arriving.

I seem to be getting a box a day.

Also bought a couple of wheels.

A 19" front wheel with brake from a 60's BSA & another 19" wheel without brake.

Hope I can use them

I'm still trying to work out what color to paint the tank, rims & back guard

I put the first coat of black on the frame .... which look ok.

Murray Morrel said I shouldn't put any bog on the frame, just powder coat as they rust from the inside & you want to be able to see the cracks !

I'm not going to change it now.

Decided to get the growing list of smaller parts powder coated though.

Much harder wearing, especially for the pedals.

I was going to collect the barrels from Wayne & get them bored as I'm expecting the pistons soon.

But wont happen as we have to rebuild the exhaust ports with an electric welder before we can bore them

sanding sanding sanding

put a 2nd coat of spray putty primer on the frame & forks .... takes ages to sand back

In hindsight I wish I had spent more time with the bog ... spray putty only hides v small imperfections

I've ended up sanding back to bare metal in spots using wet & dry & I noticed rust appearing DAMMIT

I'm hoping that wiping it clean & painting it with primer will be enough !

placed an order with Rocky at Iron Wigwam in the US for pistons .... so they should be here next week.

still need to sort out a front wheel & "leafs" for my leaf spring but should have enough to start building the engine soon.

Put a couple of coats on the leaf stays which look ok. Not perfect but I guess its a hill climber !

Not looking fwd to painting the wheel rims but I don't want chrome ! I guess preparing them will take some time.

Pistons

This bike will be stroked from 45CI to 57CI using chief flywheels.

I'm using some 1934 standard scout cases so the chief flywheels will need to be ground down to fit with sport scout barrels & rods.

As the stroke is longer we need to make sure the pistons wont come out at top/bottom. So we need pistons with smaller skirts.

Some people even cut out more room in the heads to accommodate.

The std bore on SS barrels is 2.875 but mine will be 50thou over once cleaned up.

I've heard of people using honda pistons ..... so I need to figure out which ones.

Ended up speaking to guys in Melb, Sweeden & sent a message to the virtual indian list "VI" to get the following info

Sport Scout bores

Bore size

2.875 = 73.025 mm

But we need 2.875” +.05 = 2.925” = 74.295 mm

The boys in Melb used Honda XR250 pistons but I don't think they come in 50 over part 13102-Kti-315

Jurgen built his "102" with Yamaha golf cart pistons

Welded up a little mountain in the head – to displace & improve air flow

Part j38-11635-01

Then I wrote to the virtual indian list & got the following comments

Think I'll run with option 1 for $260

Any thoughts wise masters ?

1]

Charlie,

I have NOS Rocky Cycle pistons from the Hap Jones dealership that are used for stroker scouts, they are in +.050 size, if interested contact me off list at rocky@iron wigwam

Stroker pistons to make your scout have 57 ci using chief flywheels. Brand new old stock. avaibable in +.030, +.040, +.050, +.060, +.075 over size. You get a pair of pistons, domed for use with Bonneville heads or stock heads, ewp ins, 4 clips and two complete sets of rings. This special set of pistons allows the rider to increase his engine size without adding stroker plates under the cylinders, which is a sure give way that the engine has beem leaned on or the use of intake port extensions which create intake leaks which are no fun. So with these pistons a builder can keep the stock look on the outside with a stroker on the inside.

2]

Hello Charlie

Go a little further and use One of Rockys Crank pins to suit HD Sportster Rods

and bearings and use Iron Sporster rods. The SS rods are not all that strong . I

am also in the process of building a similar Standard scout motor to you and

fitting to a 101 frame.

There are a few problems to over come.Crankcase clearance for the rods needs

adjustment, I would also fit a top head steady bracket to the frame.

Regards Phil

3]

Our Late Great Guru "Cliff" made up a top motor bracket that attached the rear of the rear head to the s/c loop under the frame. He then joined the 2 cyls with a strap from the forward of the rear head, to the rear of the front head, much like a conventional upper mount goes. But this one was anchored to the 101 frame from the top s/c mount hole. It was just easy, and didn't require a new lug on the frame.

Jus' Sayin' RF.

Cliff did over 106 mph with this 101 in Reno (which is considered high

4]

Charlie,

The old standard piston for this combo is the 2 7/8"Cushman piston. They

are available from Dennis Carpenter Cushman parts fairly quickly. they

have to be relived a tiny bit on the skirt to clear the flywheels and

will require special wrist pin bushes. The pop up is almost exactly a

Bonneville pop up. I looked and don't have any .050s just some .010s.

Dave Clements

Sport Scouts & Antique Electronics

altitude).