91
Engine & Transmission / Re: ruined Phelon flywheel keyway and crankshaft repair
« Last post by Scooter4 on October 29, 2023, 09:40:21 AM »Thank you all. It was way too much work for such a simple mistake.
Scooter
Scooter
Recent Posts
92
Frame, Tank, Seat, Controls, Etc / Re: Headlight Bulb
« Last post by Ricks on October 28, 2023, 05:47:08 PM »I also inherited my first lathe from my grandfather. It was an Atlas/Craftsman 6". I passed it along to my nephew about 12 years ago, and replaced it with a SB9A, which I still have. I supplemented it with a SB13. I also have a Millrite vertical mill. I love having these machines, it allows me to make many things.
93
Frame, Tank, Seat, Controls, Etc / Re: Headlight Bulb
« Last post by pd on October 28, 2023, 05:32:19 PM »Nice . And , that crank taper turned out good , too . 
Pete .
Pete .
94
Engine & Transmission / Re: ruined Phelon flywheel keyway and crankshaft repair
« Last post by pd on October 28, 2023, 04:50:02 PM » Gotta love it when a plan comes together .
Pete .
Pete .
95
Frame, Tank, Seat, Controls, Etc / Re: Headlight Bulb
« Last post by Scooter4 on October 28, 2023, 04:42:17 PM »I inherited this lathe and all tooling from my Grand dad. He taught me to machine.
I have a small drill press and bandsaw and a 6" lathe I bought.
love to machine.
I have a small drill press and bandsaw and a 6" lathe I bought.
love to machine.
96
Frame, Tank, Seat, Controls, Etc / Re: Headlight Bulb
« Last post by Ricks on October 28, 2023, 04:06:20 PM »OK Scott, you have to post a picture of your lathe.
97
Engine & Transmission / Re: ruined Phelon flywheel keyway and crankshaft repair
« Last post by Ricks on October 28, 2023, 04:04:38 PM »Well done sir!
98
Engine & Transmission / Re: model M right side bearing inner race direction
« Last post by Ricks on October 28, 2023, 04:02:06 PM »I turned the bearing around so the thrust would be in the correct direction and have about .015" end play now.
My inner bearing is Koyo 6205 and no spacer. I did see a note in the manual that eventually they did not need it.
Thank you,
Scooter
If you used the wide bearing, you probably wouldn't need a spacer at all. Good that you got it figured out!
99
Frame, Tank, Seat, Controls, Etc / Re: Headlight Bulb
« Last post by Scooter4 on October 28, 2023, 03:58:21 PM »I made a new headlight coil and ran it. It only barely lights the 21 cp bulb. It is 10 volt at 1.35 amps.
The amperage is low so I am wondering if my magnets are weak even though I have good ignition spark. Probably not going to mess with it anymore unless I get the flywheel charged.
New coil is:18 gauge wire at 297 turns using approximately 88 feet and .56 ohms. I made it longer also. The core is 1.00" and finished out at 1.85 x 1.85 x 1.05 long. This size is almost too big and close to rotating magnets.
Old coil is: 22 gauge wire at 310 turns using approximately 81.5 feet and 1.3 ohms and core is about 7/8" and finished out at 1.43 x 1.35.
When I installed it I was wishing I had shimmed the wide side where the bent tab goes about .015 more. It was hard to push on.
Attached are pictures of the fixture to wind it and you can see the shims I had to add because the core is a little bigger than half inch and is wider in one direction. The carboard core in the picture is from the original, I forgot to take pictures of mine.
Thank you,
Scooter
The amperage is low so I am wondering if my magnets are weak even though I have good ignition spark. Probably not going to mess with it anymore unless I get the flywheel charged.
New coil is:18 gauge wire at 297 turns using approximately 88 feet and .56 ohms. I made it longer also. The core is 1.00" and finished out at 1.85 x 1.85 x 1.05 long. This size is almost too big and close to rotating magnets.
Old coil is: 22 gauge wire at 310 turns using approximately 81.5 feet and 1.3 ohms and core is about 7/8" and finished out at 1.43 x 1.35.
When I installed it I was wishing I had shimmed the wide side where the bent tab goes about .015 more. It was hard to push on.
Attached are pictures of the fixture to wind it and you can see the shims I had to add because the core is a little bigger than half inch and is wider in one direction. The carboard core in the picture is from the original, I forgot to take pictures of mine.
Thank you,
Scooter
100
Engine & Transmission / Re: ruined Phelon flywheel keyway and crankshaft repair
« Last post by Scooter4 on October 28, 2023, 03:46:09 PM »Good evening,
The bike is running again. A welder welded both parts for me with MIG, but I had to redo the flywheel with stick because he was not able to see in there. I machined and lapped them. I was planning to spend hours hand filing the flywheel keyway, but realized I had a hacksaw with a deep enough throat and could stack four blades. When I was setting up in the vise, I realized I could use a piece of plywood that needed behind the flywheel as a guide if I cut a slot in it. Took 10 minutes and made a very nice keyway I had to file about .005" wider to fit the key. I made an aluminum key for it.
In the process of putting it back together I found what happened. I forgot to put the washer behind the gear nut and the gear had heavy rust damage to the unused threads and made me think I was tightening it.
I almost did the same thing on the repaired parts, but this time I was checking fit up and making sure there is enough thread because it ends right at the flywheel and now my flywheel is a little further on the taper from the repair clean up and lapping.
I ran it for a while and checked and seems to have stayed tight. Also used blue thread locker on the nut.
Thank you,
Scooter
The bike is running again. A welder welded both parts for me with MIG, but I had to redo the flywheel with stick because he was not able to see in there. I machined and lapped them. I was planning to spend hours hand filing the flywheel keyway, but realized I had a hacksaw with a deep enough throat and could stack four blades. When I was setting up in the vise, I realized I could use a piece of plywood that needed behind the flywheel as a guide if I cut a slot in it. Took 10 minutes and made a very nice keyway I had to file about .005" wider to fit the key. I made an aluminum key for it.
In the process of putting it back together I found what happened. I forgot to put the washer behind the gear nut and the gear had heavy rust damage to the unused threads and made me think I was tightening it.
I almost did the same thing on the repaired parts, but this time I was checking fit up and making sure there is enough thread because it ends right at the flywheel and now my flywheel is a little further on the taper from the repair clean up and lapping.
I ran it for a while and checked and seems to have stayed tight. Also used blue thread locker on the nut.
Thank you,
Scooter