Start of the winter rebuild

[JOOLZ]

I had probably the last ride of the year today, the bike will come indoors for its rebuild and supercharger fitting, looking forward to it, it looks like it will have around 77Hp so that should be fun I have made a few more parts for the bike over the Summer

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[Moto63]

Morning Joolz...best of luck with the winter rebuild, looking forward to seeing it built up. Cheers, Michael

[mthee]

Indoors? 😵

[JOOLZ]

Yes, the winter garage is the dining room Plastic sheet on the carpet, and an old carpet on top of that, the perfect garage warm, can see the tv and not far from the kitchen. 
Progress so far, the rolling chassis has been stripped cleaned and rebuilt, the electrics have been repositioned and the battery has been relocated to the tail fairing.
The supercharger has been installed, just working on the engine now, that gives me 4 months to concentrate on just 3 things, carburettor, plenum chamber and the engine mods and rebuild.
Came across one problem though, the fuel tap is in the way of the supercharger pulley, so it looks like I will have to modify the tank

[timbo]

There's always something, isn't there. Good luck with the work ahead 

[JOOLZ]

Stripped the engine down to bare cases today, cleaned inside and out removed the old gasket material and recut all the threads, its amazing how much crud builds up at the bottom of the thread drillings.
Cleaned the barrel and inspected it and recut all the threads, also decoked the piston crown and gave it a polish, thinking about spraying the top with thermal barrier coating while its out

[JOOLZ]

I have the crank extension made and a matching pulley. I also bought a new con rod for the XL600R crank.
This means I will have my original crank for sale if anyone is interested, XBR500 crank with a Hot Rods XL600 con rod and left hand bearing under 9000 miles on it built and indexed by Eastwood racing £75

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[CrazyFrog]

Sounds like a very good price to me. 

[mthee]

Yes, the winter garage is the dining room Plastic sheet on the carpet, and an old carpet on top of that, the perfect garage warm, can see the tv and not far from the kitchen. 

You really are living my dream!  I once got my bike, a 1977 T140V at the time, into the conservatory, but only briefly before we both got thrown back out!
BTW, much like your good self, I'm also a skilled mechanic and engineer ...
(OK, that bit's also part of the dream!)
Best of luck, I'll be thinking of you when I'm out in the garage, freezing my nuts off whilst agonising over whether or not to remove the cylinder head cover!

[JOOLZ]

mthee, I feel for you, I have just had to turn the central heating down its a bit warm in here
As you can see I have had to make a drastic rethink on my setup, the xbr crank put the drive line too far out with the xbr cover, and in order to correct that I would have to fit a small internal flywheel inside the xl600 alternator cover then have a sepatate external alternator plus all the associated gubbins and wiring adaptions
This way I can use the shorter xl crank, bolt the xbr stator to the xl cover and have the pulley line up, trouble is I spent a fair bit of the winter machining up an internal flywheel an end plate and a few other pieces, oh well at least its keeping my engineering skills up to date

[JOOLZ]

I have 3 different oil pumps here at the moment, the original xbr item an xl pump and an nx pump, I am going to use the nx pump as it is bigger, with the xl gearing which spins the pump faster. The nx pump is 4mm wider so I am going to make up a spacer to go between the crankcase and the clutch cover

[JOOLZ]

Just dry fitting a few componants together

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[Moto63]

Looking good Joolz, bet ya starting to get a little excited eh. Really looking forward to seeing the finished bike...cheers, Michael

[JOOLZ]

I made my own intake and fitted the carb, looks good. Im sticking to the Amal for now, maybe get a bigger carb next year

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[timbo]

Now that really looks the business