It lives!!!

Today was a big day in progress. I woke up this morning and got my son ready for church to go with my parents and off to the garage I went. After about 20 minutes both carbs were installed. It took some work to get fuel lines put back on and everything ready to start. I took her outside again and started my sequence. I first held down ticklers till I got the stinky finger on each side (due to I was cheap and didnt buy the *non stinky* kit for the carbs. I just want to note that I didnt even replace the spark plugs. I pulled them and cleaned them, then reset them to factory specifications. I kicked the bike over about 6 or 7 times and she still didnt seem like she was going to hit. I got some handy dandy starting fluid and gave her a small drink in each carb. The very next kick was when the life came back to "Lucky". She fired up and roared to life. The bike stablized at about 4000 rpm's. I definitely have some adjusting to do with the newly redone carbs. But I let it run for about 20 minutes so I do know the timing is good and it seems voltage and everything else is good. I didnt try to ride her yet but thats not far down the path now. One thing I might mention is she was leaking oil like crazy. There has been a small spot developing under her in the garage but today when she started it began dripping faster and faster until it was a full fledged gush of oil. It leads me to think the return line to the oil bag might be off or clogged or even have a hole in it. Anyway, enough talk, here is the video of her running. More updates to come soon!

Peace!

RH Carb assembled!

Today the goal was to just get the RH carb assembled. Everything was cleaned previously and JB Welded (fuel inlet). The actualy assembly sure doesnt take very long. Here are some pics of the finished carb. Tomorrow hopefully I will get them installed and try to get her to start!

RH carb fully cleaned and all sanding done!

Well, tonight the JB Weld has set up quite well and I used it to clog a hole I found (mentioned last night). I also used it to plug up the choke hole on the cable assembly that goes in the top of the carb. Tonight consisted of some sore fingers. The RH carb was not as well rounded inside the bore as the LH carb was. I used 400 grit sandpaper and wrapped my index and middle finger with paper then began to smooth out the inside of the carb. After I determined the inside was as smooth as a babies ass I went on to the slide. I sanded for about an hour to an hour and half but stopping every 20 or so strokes to see how the slide action was working inside the carb. Much like the other carb I only took enough metal off so that the spring could overcome the friction of the slide. I really am nervous about the throttle sticking so I am taking the extra time to test everything about the throttle and do not want to get caught off guard while riding "Lucky"... Yup... I finally came up with the name of the build... I am going to call her "Lucky". Havent decided if I am going to look for images from WWII with the "Lucky" girls or if I will use 4 leaf clovers. But since green is my favorite color the bike will end up with green fender and green tank more than likely. Today feels like a big accomplishment. I will try to get the rebuild kit in the RH carb tomorrow and I should be ready to install and try to start again soon!

peace!
Brian

RH Carb first manual cleaning and JB Weld installed

Well, tonight I started on the RH carb... It was not nearly as dirty as the LH carb however the air mixture hole was totally clogged and took about 30 minutes to get it unclogged. I tried everything from tiny wire to toothpicks and compressed air. It was being a total bitch. After over an hour of cleaning it was ready to leave for the night and resume work tomorrow. During dis assembly I noticed the plug that was in the choke hole was moving a bit. So I put some pressure on it with a small allen wrench and it came OUT!! It was CORK... you have to be kidding... who would put cork in the top of a carburetor that is a vacuum source with constant pull. Eventually that thing was going to come loose and go inside the engine or who knows what... So I kept cleaning. I reached the bottom of the carb and removed the fuel inlet adapter that connects to the bottom of the bowl. After a thorough cleaning I noticed an odd indention in the side. It seems like there was something jammed in the side. Another freaking piece of cork.. Yeah.. cork to hold in the fuel. The fuel pressure was always pusing this thing outward. No wonder the carb leaked like a sprinkler. There is a hole just a tad smaller than a pencil eraser in the fuel inlet. So I sanded it down very very well and cleaned the surfaces. JB Weld to the rescue!! Time for some rest... 2 suprises is enough... More updates tomorrow!

LH Carb is fully assembled!

Well, after some a ton of sandpaper working on the inner barrel and the slide it moves (not easily, but the friction from the slide movement is less than the strength of the spring that controls the movement) I have the LH carb fully assembled. Now since I elected to not disassemble the throttle at the handle bar I have to put the cable in then install the carb on the bike at the same time. So as much as can be done is done to the LH carb. It has a full rebuild kit in it and is checked with tolerances. I am quite proud of this carb as I would happily use it and stand behind the work i did on it.

LH Carb is almost done

After all the cleaning on the LH carb I was inserting the slide into the body of the carb and I noticed it sticks at the top of the movement. Almost like something was gummed up in there (which we know it isn't due to I just cleaned it). So I go on the internet today and read all about Amal carbs and how if some blunder-head tightens it too much then it will warp the carb body and the slide will stick... ugg... So I look into how to fix it. After quite a few searches I find a company that wants to bore out the body, insert a sleeve over the slide and that should fix it.. So I keep reading.. it is 79.99 per carb and 12.00 shipping... Ok... WTF! A new carb isi about 150.00 and then it will have new ticklers and all... So here was what I did, I got some 400 grit sandpaper from the garage and about a dab of WD-40. I wrapped the paper around my index and middle finger and proceeded to removing the area of the housing and the slide that have visible wear marks. ~~ Very slowly ~~ and checking every 2 or so strokes. After about 20 minutes the slide is still tough to move but not as tough as the spring is strong that controls its movement. It appears that I have averted the 92.00 for a used carb sleeve. But time will tell as we get her started. I should get LH carb assembled tonight (providing Lowe's has a bolt to fit the choke hole I am trying to plug!). Felt like a great day on the LH Carb. RH carb is still taking its bath in mineral spirits. Here are your images to show how it came out!

2nd carb left in solvent!

I took the other carb apart tonight and put it in the solvent to clean. I figure in a day or two I will be ready to do some scraping and final cleaning of the second carb. It wont be long after that!

LH Carb disassembly and now cleaned!

Today was the day to disassemble my first Amal Carb. Yup... my first time... I started out by removing it from the bike and taking careful note how the throttle cable was removed from the carb. When I got it inside, Monica took some great pictures for you all of the dis assembly. I could not believe what it looked like inside. I am so glad the bike didnt start last week and ruin the engine with this crap! Here is a slide-show and a link to the images!

http://s48.photobucket.com/albums/f250/Blurg01/LH%20Carb%20-%20BSA/?albumview=slideshow

Watch carefully towards the end of the video. The audio kinda breaks up but that is fire in the hole baby... rawr... fire in the hole!!!

Good exercise for fat boy!

Take 1

Stupid batteries...

Petcocks are in!

Entire family is sick but today the new petcocks came in and I just had to put one on to make sure they are the right ones! Battery is ready to go also.

At this point here is what is left:
1) Install other Petcock
2) Change fluids
3) Install Battery

After these 3 quick tasks I should be able to see if she is ready to roll or if she needs more attention. Still not positive the carbs are ready to go but I will deal with that bridge when I get to it.